Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06810-08 PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06810-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06810-08 – PDF DOWNLOAD

Language : English
Pages :2962
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06810-08 – PDF DOWNLOAD

SERIAL NUMBERS 90825 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06810-08 – PDF DOWNLOAD

SERIAL NUMBERS 90825 and up

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 (Applicable Machine: 90156 to 92053) 107
Layout Drawing of Urea SCR System (Applicable Machine: 92054 and up) 112
Urea SCR System Diagram 116
Function of Urea SCR System 117
Function of DEF System (Applicable Machine: 90156 to 92053) 117
Function of DEF System (Applicable Machine: 92054 and Up) 119
Inducement Strategy 121
Component Parts of Urea SCR System 129
DEF Mixing Tube 129
SCR Assembly 129
DEF Tank 132
DEF Pump 134
DEF Injector 136
DEF Hose 137
DEF Tank Heating Valve 138
Boot-up System 139
Layout Drawing of Boot-up System 139
System Operating Lamp System 141
System Diagram of System Operating Lamp System 141
Function of Operation Lamp System 141
Battery Isolator 143
Function of Battery Isolator 143
Engine System 144
Layout Drawing of Engine System 144
Specifications of Engine System 145
Function of Engine System 145
Engine Control System 146
System Diagram of Engine Control 146
Function of Engine Control System 147
Auto-Deceleration System 150
System Diagram of Auto-Deceleration System 150
Function of Auto-Deceleration System 150
Operation of Auto-Deceleration System 151
Engine Automatic Warm-up System 152
System Diagram of Engine Automatic Warm-up System 152
Function of Engine Automatic Warm-up System 153
Overheat Prevention System 154
Overheat Prevention System Diagram 154
Function of Overheat Prevention System 155
Turbocharger Protection System 156
System Diagram of Turbocharger Protection System 156
Function of Turbocharger Protection System 157
Automatic Idle Stop System 158
System Diagram of Automatic Idle Stop System 158
Function of Automatic Idle Stop System 158
Component Parts of Engine System 161
VGT 161
EGR System 164
EGR Valve 166
EGR Cooler 168
KCCV System 169
KCCV Ventilator 171
KDPF 172
Cooling System 177
Layout Drawing of Cooling System 177
Specifications of Cooling System 178
Control System 179
Layout Drawing of Control System 179
Machine Monitor System 182
System Diagram of Machine Monitor System 182
Function of Machine Monitor System 182
KomVision System 184
Layout Drawing of KomVision System 184
System Diagram of KomVision System 186
Function of KomVision System 186
KOMTRAX System 188
System Diagram of KOMTRAX System 188
Function of KOMTRAX System 188
PPC Levers 189
LH PPC Lever 189
RH PPC Lever 190
Automatic Grease System 191
Outline of AUTO Grease System 191
Component Parts of Control System 203
Machine Monitor 203
KomVision Controller 216
KomVision Camera 220
Gateway Function Controller 221
Communication Terminal 224
Pump Controller 226
Resistor for PC-EPC Valve 230
CAN Terminating Resistor 231
PPC Oil Pressure Switch 231
Engine Controller 233
Fuel Control Dial 239
Hydraulic System 241
Layout Drawing of Hydraulic System 241
CLSS 244
Structure of CLSS 244
Operation of Unload Valve and LS Pressure 246
Pump Swash Plate Angle (Oil Flow) Control 247
Pressure Compensation Control 263
Engine and Pump Combined Control System 267
Engine and Pump Combined Control System Diagram 267
Function of Engine and Pump Combined Control System 268
Pump and Valve Control System 273
Pump and Valve Control System Diagram 273
Function of Pump and Valve Control System 274
Component Parts of Hydraulic System 276
Hydraulic Tank 276
Main Pump 279
Pilot Oil Filter 305
Control Valve 305
Work Equipment System 367
Layout Drawing of Work Equipment System 367
Structure of Valve Control 373
One-Touch Power Maximizing System 375
System Diagram of One-Touch Power Maximizing System 375
Function of One-Touch Power Maximizing System 376
Machine Push-up System 377
Machine Push-up System Diagram 377
Function of Machine Push-up System 378
PPC Lock System 379
System Diagram of PPC Lock 379
Function of PPC Lock System 379
Work Equipment and Travel Automatic Lock System 380
System Diagram of Lock Lever Automatic Lock System 380
Function of Work Equipment and Travel Automatic Lock System 380
Operation of Lock Lever Automatic Lock System 381
Attachment Oil Flow Adjuster System 382
Attachment Oil Flow Adjuster System Diagram 382
Function of Attachment Oil Flow Adjuster System 383
Component Parts of Work Equipment System 384
Work Equipment and Swing PPC Valve 384
1st-Line Attachment PPC Valve (with EPC Valve) 390
2nd-Line Attachment PPC Valve 394
Solenoid Valve 396
Boom Anti-drop Valve 399
Arm Anti-Drop Valve 403
Attachment Circuit Selector Valve 407
Pilot Circuit Accumulator 410
Swing System 411
Layout Drawing of Swing System 411
Swing Control System Diagram 414
Function of Swing Control System 414
Component Parts of Swing System 418
Swing Motor 418
Swing Machinery 429
Swing Circle 431
Travel System 432
Layout Drawing of Travel System 432
System Diagram of Travel Control System 436
Function of Travel Control System 436
Component Parts of Travel System 438
Travel Motor 438
Final Drive 450
Travel PPC Valve 451
Center Swivel Joint 456
Undercarriage and Frame 458
Layout Drawing of Undercarriage 458
Specifications of Undercarriage 458
Work Equipment 460
Structure of Work Equipment 460
Function of Work Equipment 461
Work Equipment Clearance Adjustment Shim 462
Function of Work Equipment Clearance Adjustment Shim 462
Bucket Clearance Adjustment Shim 463
Function of Bucket Clearance Adjustment Shim 463
CAB Related Parts 464
ROPS CAB 464
Structure of ROPS CAB 464
Function of ROPS CAB 464
CAB Mount 465
Structure of CAB Mount 465
Function of CAB Mount 465
CAB Tipping Stopper 466
Structure of CAB Tipping Stopper 466
Function of CAB Tipping Stopper 466
20 Standard Value Table 467
Table of Contents 468
Standard Value Table for Engine 469
Standard Value Table for Engine: PC360LC-11 469
Standard Value Table for Machine 474
Standard Value Table for Machine: PC360LC-11 474
Machine Posture and Procedures to Measure Performance 489
Standard Value Table for Electricity 493
Standard Value Table for Electricity 493
30 Testing and Adjusting 503
Table of Contents 504
Precautions Before Work 507
Related Information on Testing and Adjusting 508
Tools for Testing and Adjusting 508
Sketch of Tools for Testing and Adjusting 515
Engine and Cooling System 517
Examine Engine Speed 517
How to Examine Engine Speed 517
Examine Boost Pressure 521
How to Examine Boost Pressure on Machine Monitor 521
How to Examine Boost Pressure by Testing Tool 522
Examine Exhaust Gas Color 523
How to Examine Exhaust Gas Color with the Handy Smoke Checker 523
How to Examine Exhaust Gas Color with Smoke Meter 524
Examine Mass Air Flow and Temperature Sensor 525
How to Examine Mass Air Flow and Temperature Sensor 525
Examine and Adjust Valve Clearance 527
How to Examine Valve Clearance 527
How to Adjust Valve Clearance 529
Examine Compression Pressure 530
How to Examine Compression Pressure 530
Examine Blowby Pressure 533
How to Examine Blowby Pressure 533
Examine Engine Oil Pressure 535
How to Examine Engine Oil Pressure 535
Examine EGR Valve and VGT Oil Pressure 537
How to Examine EGR Valve and VGT Oil Pressure 537
Examine Fuel Pressure 539
How to Examine Fuel Pressure 540
Examine Fuel Discharge, Return and Leakage 546
How to Examine Fuel Discharge, Return, and Leakage 547
Bleed Air from Fuel System 553
How to Bleed Air from Fuel System 553
Examine Fuel Circuit for Leakage 554
How to Examine Fuel System for Leakage 554
Handle Cylinder Cut-out Mode Operation 556
Handle No-Injection Cranking Operation 557
Examine and Adjust Air Conditioner Compressor Belt Tension 558
How to Examine Air Conditioner Compressor Belt Tension 558
How to Adjust Air Conditioner Compressor Belt Tension 558
How to Adjust Air Conditioner Compressor Belt 559
Examine Alternator Belt 560
How to Examine Alternator Belt 560
Examine Automatic Tensioner 561
How to Examine Automatic Tensioner 561
How to Replace Fan Belt 562
Write Correction for Ash in Soot Accumulation to Engine Controller 563
How to Write Correction for Ash in Soot Accumulation to Engine Controller 563
Examine SCR Related Functions 564
Examine DEF Pump Raised Pressure 567
Examine Injection Volume from DEF Injector 570
Examine DEF Line Heater Relay 1 573
Examine DEF Line Heater Relay 2 578
Examine DEF Pump Heater Relay 581
Examine DEF Tank Heater Valve 584
Examine SCR Denitration Efficiency 587
Clean DEF Tank 591
How to Clean DEF Tank 591
Clean DEF Pump 595
How to Clean DEF Pump 595
Power Train 601
Examine Swing Circle Bearing Clearance 601
How to Examine Swing Circle Bearing Clearance 601
Undercarriage and Frame 602
Examine and Adjust Track Tension 602
How to Examine Track Tension 602
How to Adjust Track Tension 602
Hydraulic System 604
Release Remained Pressure in Hydraulic Circuit 604
How to Release Remained Pressure from Hydraulic Tank 604
How to Release Remained Pressure in Hydraulic Cylinder Circuit 604
How to Release Remained Pressure from Swing Motor Circuit 608
How to Release Remained Pressure from Travel Motor Circuit 608
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 609
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 610
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 618
Examine Oil Pressure of Control Circuit 621
How to Examine Oil Pressure in Control Circuit 621
Examine and adjust oil pressure in pump PC control circuit 623
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 623
Examine PC-EPC Valve Outlet Pressure 624
How to Adjust Oil Pressure in Pump PC Control Circuit 625
Examine and Adjust Oil Pressure in Pump LS Control Circuit 626
How to Examine LS Differential Pressure with Machine Monitor 626
How to Examine LS Differential Pressure by Testing Tool 627
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 629
How to Examine LS-EPC Valve Outlet Pressure 629
How to Adjust LS Valve 630
Examine Outlet Pressure of Solenoid Valve 631
How to Examine Outlet Pressure of Solenoid Valve 631
Operating Condition of Solenoid Valve 632
Examine PPC Valve Outlet Pressure 634
How to Examine Outlet Pressure in PPC Valve 634
Adjust Play of Work Equipment and Swing PPC Valves 636
How to Adjust Play of Work Equipment and Swing PPC Valves 636
Measure and Adjust Quick Coupler Control Valve Output Pressure 637
Examine Pump Swash Plate Sensor 639
How to Examine pump swash plate sensor 639
Examine Parts Which Cause Hydraulic Drift of Work Equipment 640
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 640
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 640
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 641
Examine Oil Leakage 642
How to Examine Oil Leakage from Boom Cylinder 642
How to Examine Oil Leakage from Arm Cylinder 642
How to Examine Oil Leakage from Bucket Cylinder 643
How to Examine Oil Leakage from Swing Motor 643
How to Examine Oil Leakage from Travel Motor 644
Bleed Air from Hydraulic System 645
How to Bleed Air from Hydraulic System 647
CAB Related Parts 650
Examine CAB Tipping Stopper 650
How to Examine Cab Tipping Stopper 650
How to Adjust Mirrors 651
Procedure to Adjust Machine Left Front Mirror (A) 651
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 652
Procedure to Adjust Machine Right Front Mirror (B) 653
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 654
Procedure to Adjust Machine Right Side Mirror (C) 655
Electrical System 657
Set and Operate Machine Monitor 657
Operator Mode 660
Function to Show Technician Identification Status Screen 661
Function to Show Operator Identification Input Screen 661
Examine Function by LCD (Liquid Crystal Display) 662
Examine Function of Service Meter 662
Usage Limitation and Maintenance Password Change Function 662
Service Mode 665
How to Operate Service Mode 665
How to See Pre-defined Monitoring Information 667
How to Examine Self-Define Monitor Information 674
Abnormality Record Menu 684
How to See Maintenance Record 689
Maintenance Mode Setting 690
How to Set Phone Number Entry 694
Default Menu 695
Diagnostic Tests Menu 703
Adjustment Menu 713
No-Injection Cranking Operation 734
KOMTRAX Settings Menu 735
How to Show Service Message 737
How to Start Up KOMTRAX System 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 Isolator 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 781
40 Troubleshooting 797
Table of Contents 798
Precautions Before Work 809
Related Information to Troubleshooting 810
General Troubleshooting Points 810
Troubleshooting Points for Urea SCR System 811
Sequence of Events in Troubleshooting 825
Checks Before Troubleshooting 827
Inspection Procedure Before Troubleshooting 829
Walk-Around Check 829
Test in Accordance with Testing Procedure 831
Examine Fuel Level and Type 831
Examine for Impure Ingredient in Fuel 831
Examine Fuel Prefilter 832
Examine Water Separator, Drain Water and Sediment 832
How to Replace Fuel Prefilter Cartridge 833
Examine Fuel Main Filter 834
Examine Engine Oil Level (Oil Quantity in Oil Pan) 836
Examine Coolant Level (Expansion Tank) 837
Examine Air Cleaner Clogging 838
Clean Outer Element 838
Replace Element 841
Examine Hydraulic Oil Level 842
Examine Hydraulic Oil Strainer 843
Examine Hydraulic Oil Filter 844
Examine Oil Level in Swing Machinery Case 844
Examine Oil Level in Damper Case 845
Examine Oil Level in Final Drive Case 846
Bleed Air from Fuel System 846
Bleed Air from Hydraulic System 846
How to Examine Electric Equipment 846
Automatic Grease System 851
Find Malfunctions 851
Malfunction Finding Procedures 853
Preparation for Troubleshooting of Electrical System 855
Procedure for Troubleshooting 868
Symptom and Troubleshooting Numbers 871
Information Shown in Troubleshooting Table 875
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 877
Connector List and Layout 880
Connector Contact Connection Table 893
T-Branch Box and T-Branch Adapter Table 933
Fuse Location Table 939
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 942
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 946
Failure Code Table 948
Troubleshooting by Failure Code (Display of Code) 967
Failure Code [6AZ0ZG] 967
Failure Code [879AKA] 969
Failure Code [879AKB] 970
Failure Code [879BKA] 971
Failure Code [879BKB] 973
Failure Code [879CKA] 975
Failure Code [879CKB] 976
Failure Code [879DKZ] 977
Failure Code [879EMC] 979
Failure Code [879FMC] 980
Failure Code [879GKX] 981
Failure Code [989L00] 983
Failure Code [989M00] 984
Failure Code [989N00] 985
Failure Code [A1U0N3] 986
Failure Code [A1U0N4] 988
Failure Code [A900FR] 990
Failure Code [A900N6] 991
Failure Code [A900NY] 992
Failure Code [AA10NX] 993
Failure Code [AB00KE] 995
Failure Code [AQ10N3] 998
Failure Code [AS00N3]1000
Failure Code [AS00R2]1002
Failure Code [AS00R3]1003
Failure Code [AS00R4]1004
Failure Code [AS00R5]1005
Failure Code [AS00R6]1006
Failure Code [AS00ZK]1007
Failure Code [AS10KM]1008
Failure Code [AS10NR]1009
Failure Code [AS10NT]1010
Failure Code [B@BAZG]1011
Failure Code [B@BAZK]1012
Failure Code [B@BCNS]1014
Failure Code [B@BCQA]1015
Failure Code [B@BCZK]1017
Failure Code [B@HANS]1019
Failure Code [CA115]1020
Failure Code [CA122]1021
Failure Code [CA123]1023
Failure Code [CA131]1025
Failure Code [CA132]1027
Failure Code [CA144]1029
Failure Code [CA145]1031
Failure Code [CA153]1033
Failure Code [CA154]1036
Failure Code [CA187]1039
Failure Code [CA221]1041
Failure Code [CA222]1043
Failure Code [CA227]1045
Failure Code [CA234]1046
Failure Code [CA238]1047
Failure Code [CA239]1049
Failure Code [CA249]1051
Failure Code [CA256]1053
Failure Code [CA271]1055
Failure Code [CA272]1057
Failure Code [CA281]1059
Failure Code [CA322]1060
Failure Code [CA323]1062
Failure Code [CA324]1064
Failure Code [CA325]1066
Failure Code [CA331]1068
Failure Code [CA332]1070
Failure Code [CA343]1072
Failure Code [CA351]1073
Failure Code [CA352]1074
Failure Code [CA356]1077
Failure Code [CA357]1079
Failure Code [CA386]1081
Failure Code [CA428]1082
Failure Code [CA429]1084
Failure Code [CA435]1086
Failure Code [CA441]1088
Failure Code [CA442]1091
Failure Code [CA449]1092
Failure Code [CA451]1096
Failure Code [CA452]1099
Failure Code [CA488]1101
Failure Code [CA515]1102
Failure Code [CA516]1104
Failure Code [CA553]1106
Failure Code [CA555]1107
Failure Code [CA556]1108
Failure Code [CA559]1109
Failure Code [CA595]1113
Failure Code [CA687]1114
Failure Code [CA689]1116
Failure Code [CA691]1121
Failure Code [CA692]1123
Failure Code [CA697]1125
Failure Code [CA698]1126
Failure Code [CA731]1127
Failure Code [CA778]1129
Failure Code [CA1117]1134
Failure Code [CA1664]1135
Failure Code [CA1669]1137
Failure Code [CA1673]1138
Failure Code [CA1677]1139
Failure Code [CA1678]1140
Failure Code [CA1682]1141
Failure Code [CA1683]1143
Failure Code [CA1684]1145
Failure Code [CA1686]1147
Failure Code [CA1691]1148
Failure Code [CA1694]1151
Failure Code [CA1695]1154
Failure Code [CA1696]1155
Failure Code [CA1712]1157
Failure Code [CA1713]1160
Failure Code [CA1714]1162
Failure Code [CA1715]1163
Failure Code [CA1776]1164
Failure Code [CA1777]1167
Failure Code [CA1843]1170
Failure Code [CA1844]1172
Failure Code [CA1879]1175
Failure Code [CA1881]1178
Failure Code [CA1883]1180
Failure Code [CA1885]1183
Failure Code [CA1887]1185
Failure Code [CA1921]1187
Failure Code [CA1922]1190
Failure Code [CA1942]1195
Failure Code [CA1993]1196
Failure Code [CA2185]1199
Failure Code [CA2186]1201
Failure Code [CA2249]1203
Failure Code [CA2265]1204
Failure Code [CA2266]1206
Failure Code [CA2271]1208
Failure Code [CA2272]1211
Failure Code [CA2288]1214
Failure Code [CA2311]1215
Failure Code [CA2349]1216
Failure Code [CA2353]1219
Failure Code [CA2357]1221
Failure Code [CA2381]1222
Failure Code [CA2382]1225
Failure Code [CA2383]1228
Failure Code [CA2386]1231
Failure Code [CA2387]1233
Troubleshooting Flowchart1237
Failure Code [CA2555]1238
Failure Code [CA2556]1241
Failure Code [CA2637]1244
Failure Code [CA2639]1246
Failure Code [CA2771]1249
Failure Code [CA2777]1255
Failure Code [CA2976]1258
Failure Code [CA3133]1260
Failure Code [CA3134]1262
Failure Code [CA3135]1264
Failure Code [CA3142]1267
Failure Code [CA3143]1268
Failure Code [CA3144]1269
Failure Code [CA3146]1271
Failure Code [CA3147]1272
Failure Code [CA3148]1273
Failure Code [CA3151]1275
Failure Code [CA3165]1281
Failure Code [CA3229]1283
Failure Code [CA3231]1285
Failure Code [CA3232]1287
Failure Code [CA3235]1291
Failure Code [CA3239]1293
Failure Code [CA3241]1296
Failure Code [CA3242]1299
Failure Code [CA3251]1302
Failure Code [CA3253]1304
Failure Code [CA3254]1307
Failure Code [CA3255]1310
Failure Code [CA3256]1314
Failure Code [CA3311]1316
Failure Code [CA3312]1318
Failure Code [CA3313]1321
Failure Code [CA3314]1322
Failure Code [CA3315]1323
Failure Code [CA3316]1325
Failure Code [CA3317]1326
Failure Code [CA3318]1327
Failure Code [CA3319]1329
Failure Code [CA3321]1330
Failure Code [CA3322]1332
Failure Code [CA3419]1334
Failure Code [CA3421]1336
Failure Code [CA3497]1338
Failure Code [CA3498]1339
Failure Code [CA3543]1340
Failure Code [CA3545]1347
Failure Code [CA3547]1349
Failure Code [CA3558]1350
Failure Code [CA3559]1352
Failure Code [CA3562]1354
Failure Code [CA3563]1356
Failure Code [CA3567]1359
Failure Code [CA3568]1362
Failure Code [CA3571]1366
Failure Code [CA3572]1368
Failure Code [CA3574]1370
Failure Code [CA3575]1372
Failure Code [CA3577]1374
Failure Code [CA3578]1376
Failure Code [CA3582]1378
Failure Code [CA3583]1384
Failure Code [CA3596]1386
Failure Code [CA3649]1388
Failure Code [CA3681]1390
Failure Code [CA3682]1395
Failure Code [CA3713]1400
Failure Code [CA3717]1403
Failure Code [CA3718]1404
Failure Code [CA3725]1405
Failure Code [CA3741]1408
Failure Code [CA3748]1409
Failure Code [CA3751]1411
Failure Code [CA3755]1413
Failure Code [CA3866]1415
Failure Code [CA3867]1419
Failure Code [CA3868]1422
Failure Code [CA3899]1426
Failure Code [CA3911]1428
Failure Code [CA3912]1432
Failure Code [CA3932]1434
Failure Code [CA3933]1436
Failure Code [CA3934]1438
Failure Code [CA3935]1441
Failure Code [CA3936]1443
Failure Code [CA4151]1445
Failure Code [CA4152]1449
Failure Code [CA4155]1453
Failure Code [CA4156]1456
Failure Code [CA4157]1459
Failure Code [CA4158]1461
Failure Code [CA4159]1462
Failure Code [CA4161]1463
Failure Code [CA4162]1466
Failure Code [CA4163]1469
Failure Code [CA4164]1471
Failure Code [CA4165]1473
Failure Code [CA4166]1475
Failure Code [CA4168]1477
Failure Code [CA4169]1480
Failure Code [CA4171]1482
Failure Code [CA4249]1485
Failure Code [CA4251]1487
Failure Code [CA4259]1489
Failure Code [CA4261]1492
Failure Code [CA4277]1495
Failure Code [CA4281]1499
Failure Code [CA4459]1502
Failure Code [CA4461]1505
Failure Code [CA4658]1508
Failure Code [CA4731]1512
Failure Code [CA4732]1513
Failure Code [CA4739]1514
Failure Code [CA4768]1515
Failure Code [CA4769]1517
Failure Code [CA4842]1520
Failure Code [CA4952]1524
Failure Code [CA5115]1526
Failure Code [CA5179]1529
Failure Code [CA5181]1531
Failure Code [CA5383]1533
Failure Code [D110KB]1535
Failure Code [D19JKZ]1537
Failure Code [D811MC]1540
Failure Code [D862KA]1541
Failure Code [D8ALKA]1543
Failure Code [D8ALKB]1546
Failure Code [D8AQKR]1548
Failure Code [D8G1KT]1555
Failure Code [D8G6KT]1556
Failure Code [DA20MC]1557
Failure Code [DA22KK]1558
Failure Code [DA25KP]1561
Failure Code [DA29KQ]1564
Failure Code [DA2LKA]1566
Failure Code [DA2LKB]1569
Failure Code [DA2QKR]1571
Failure Code [DA2RKR]1580
Failure Code [DAF0KM]1581
Failure Code [DAF0MB]1582
Failure Code [DAF0MC]1583
Failure Code [DAF8KB]1584
Failure Code [DAF9KQ]1586
Failure Code [DAFGMC]1587
Failure Code [DAFLKA]1588
Failure Code [DAFLKB]1591
Failure Code [DAFQKR]1593
Failure Code [DAZ9KQ]1601
Failure Code [DAZQKR]1602
Failure Code [DB2QKR]1609
Failure Code [DB2RKR]1617
Failure Code [DBP0KM]1622
Failure Code [DBP0KT]1623
Failure Code [DBP5KB]1624
Failure Code [DBP5KY]1627
Failure Code [DBPQKR]1630
Failure Code [DDNRKA]1638
Failure Code [DDNRKY]1640
Failure Code [DDNS00]1642
Failure Code [DFB1KZ]1644
Failure Code [DFB2KZ]1646
Failure Code [DFB3L8]1648
Failure Code [DFB4L8]1650
Failure Code [DFB5KZ]1652
Failure Code [DFB6KZ]1654
Failure Code [DGH2KB]1656
Failure Code [DHA4KA]1658
Failure Code [DHAAMA]1660
Failure Code [DHACMA]1662
Failure Code [DHPAMA]1664
Failure Code [DHPBMA]1667
Failure Code [DHS3MA]1670
Failure Code [DHS4MA]1673
Failure Code [DHS8MA]1676
Failure Code [DHS9MA]1679
Failure Code [DHSAMA]1682
Failure Code [DHSBMA]1685
Failure Code [DHSCMA]1688
Failure Code [DHSDMA]1691
Failure Code [DHSFMA]1694
Failure Code [DHSGMA]1697
Failure Code [DHSHMA]1700
Failure Code [DHSJMA]1703
Failure Code [DHX1MA]1706
Failure Code [DKR0MA]1708
Failure Code [DKR1MA]1711
Failure Code [DKULKA]1714
Failure Code [DKULKB]1716
Failure Code [DKULKY]1718
Failure Code [DR10KA]1720
Failure Code [DR12KA]1723
Failure Code [DR20KA]1725
Failure Code [DR21KX]1727
Failure Code [DR30KA]1729
Failure Code [DR31KX]1731
Failure Code [DR40KA]1733
Failure Code [DUMBKA]1735
Failure Code [DUMBKB]1738
Failure Code [DV20KB]1740
Failure Code [DW43KA]1742
Failure Code [DW43KB]1744
Failure Code [DW43KY]1746
Failure Code [DW45KA]1748
Failure Code [DW45KB]1751
Failure Code [DW45KY]1754
Failure Code [DW4CKY]1756
Failure Code [DW91KA]1757
Failure Code [DW91KB]1759
Failure Code [DW91KY]1761
Failure Code [DWA2KA]1763
Failure Code [DWA2KB]1765
Failure Code [DWA2KY]1767
Failure Code [DWK0KA]1769
Failure Code [DWK0KB]1771
Failure Code [DWK0KY]1773
Failure Code [DWK2KA]1775
Failure Code [DWK2KB]1777
Failure Code [DWK2KY]1779
Failure Code [DWK8KA]1781
Failure Code [DWK8KB]1783
Failure Code [DWK8KY]1785
Failure Code [DXA8KA]1787
Failure Code [DXA8KB]1790
Failure Code [DXA9KA]1792
Failure Code [DXA9KB]1795
Failure Code [DXE0KA]1797
Failure Code [DXE0KB]1799
Failure Code [DXE4KA]1801
Failure Code [DXE4KB]1803
Failure Code [DXE4KY]1805
Failure Code [DXE5KA]1806
Failure Code [DXE5KB]1808
Failure Code [DXE6KA]1810
Failure Code [DXE6KB]1812
Failure Code [DXE7KA]1814
Failure Code [DXE7KB]1816
Failure Code [DXE7KY]1818
Failure Code [DXE8KA]1820
Failure Code [DXE8KB]1822
Failure Code [DXE8KY]1824
Failure Code [DXE9KA]1826
Failure Code [DXE9KB]1828
Failure Code [DXE9KY]1830
Failure Code [DXEAKA]1832
Failure Code [DXEAKB]1834
Failure Code [DXEAKY]1836
Failure Code [DY20KA]1838
Failure Code [DY20MA]1841
Failure Code [DY2CKB]1843
Failure Code [DY2DKB]1846
Failure Code [DY2EKB]1848
Failure Code [F311KA]1850
Failure Code [F311KB]1852
Failure Code [F312KA]1854
Failure Code [F312KB]1856
Failure Code [F313KA]1858
Failure Code [F313KB]1860
Failure Code [F314KA]1863
Failure Code [F314KB]1865
Failure Code [F315KB]1867
Failure Code [F315KY]1869
Failure Code [F316KB]1871
Failure Code [F316KY]1873
Failure Code [F318KB]1875
Failure Code [F318KY]1878
Failure Code [F31AKB]1880
Failure Code [F31AKY]1882
Failure Code [F31BKB]1884
Failure Code [F31BKY]1886
Failure Code [F31CKB]1888
Failure Code [F31CKY]1890
Failure Code [F31DKB]1892
Failure Code [F31DKY]1894
Failure Code [F31EKB]1896
Failure Code [F31EKY]1898
Troubleshooting of Electrical System (E-Mode)1900
E-1 Engine Does Not Start (Engine Does Not Crank)1900
E-2 Manual Preheating System Does Not Operate1906
E-3 Automatic Preheating System Does Not Operate1909
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1911
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1913
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1916
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1917
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1918
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1919
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1920
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1921
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1922
E-13 Water Separator Monitor Comes On in Red While Engine Runs1923
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1924
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1925
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1926
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1927
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1929
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1930
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1931
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1932
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1934
E-23 Some Areas of Machine Monitor Screen are Not Shown1935
E-24 Function Switch Does Not Operate1936
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1937
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1938
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1939
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1940
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1941
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1942
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1943
E-32 Alarm Buzzer Cannot be Canceled1945
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1946
E-34 Service Mode Cannot be Selected1947
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1948
E-36 All Work Equipment, Swing and Travel Do Not Lock1950
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1951
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1954
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1956
E-40 One-Touch Power Maximizing Function is Not Cancelled1958
E-41 Alarm Does Not Sound During Travel1959
E-42 Alarm Does Not Stop When Machine Stops1961
E-43 Horn Does Not Sound1962
E-44 Horn Does Not Stop1966
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1968
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1969
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1971
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1972
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1973
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1974
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1975
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1976
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1977
E-54 “Swing” is Not Shown Correctly with Monitoring Function1978
E-55 “Travel” is Not Shown Correctly with Monitoring Function1979
E-56 Service is Not Shown Correctly with Monitoring Function1980
E-57 Attachment Hydraulic Circuit Cannot be Changed1982
E-58 KOMTRAX System Does Not Operate Correctly1983
E-59 Machine Push-Up Function is Not Canceled1984
E-60 Machine Push-Up Function Does Not Operate1986
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1987
Information Shown in Troubleshooting Table (H-Mode)1987
System Chart of Hydraulic and Mechanical Systems1988
Failure Mode and Cause Table1990
H-1 All Work Equipment, Swing and Travel Do Not Work2001
H-2 All Work Equipment, Swing and Travel Lack Speed and Power2002
H-3 Fine Control Performance or Response is Unsatisfactory2005
H-4 Unusual Noise is Heard from Around Hydraulic Pump2006
H-5 Engine Speed Drops Largely or Engine Stops2007
H-6 Speed or Power of Boom is Low2009
H-7 Arm Speed or Power is Low2015
H-8 Bucket Speed or Power is Low2020
H-9 Work Equipment Does Not Move in Single Operation2024
H-10 Hydraulic Drift of Boom is Large2025
H-11 Hydraulic Drift of Arm is Large2027
H-12 Hydraulic Drift of Bucket is Large2029
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves2030
H-14 Time Lag of Work Equipment is Large2031
H-15 One-Touch Power Maximizing Function Does Not Operate2032
H-16 Machine Push-Up Function Does Not Operate2033
H-17 Attachment Circuit Cannot be Changed2034
H-18 Oil Flow in Attachment Circuit Cannot be Changed2035
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower2036
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely2037
H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low2038
H-22 Machine Does Not Travel Straight2039
H-23 Machine is Not Steered Correctly or Steering Power is Low2041
H-24 Travel Speed is Low2044
H-25 One of Tracks Does Not Run2046
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2048
H-27 Machine Does Not Swing to Right or Left2049
H-28 Upper Structure Swings Only to Right or Left2050
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left2051
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction2052
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2053
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2054
H-33 Shock is Large When Upper Structure Stops Swing Operation2055
H-34 There is Large Unusual Noise When It Stops Swing Operation2056
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2057
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2058
H-37 Quick coupler cylinder will not extend2059
H-38 Quick coupler cylinder will not retract (but buzzer does not sound)2061
H-39 Buzzer Does Not Operate (but Quick Coupler Cylinder Does Retract)2063
H-40 Quick coupler cylinder extends and retracts slowly2064
Troubleshooting of Engine (S-Mode)2065
Information Shown in Troubleshooting Table (S-Mode)2065
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position2066
S-2 Engine Cranks but No Exhaust Smoke Comes Out2067
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2068
S-4 Engine Startability is Unsatisfactory2070
S-5 Engine Does Not Pick Up Smoothly2072
S-6 Engine Stops During Operation2074
S-7 Engine Runs Rough or is Not Stable2076
S-8 Engine Lacks Power2077
S-9 KDPF Becomes Clogged in a Short Time2079
S-10 Engine Oil Consumption is Excessive2081
S-11 Oil Becomes Dirty Quickly2082
S-12 Fuel Consumption is Excessive2083
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant2084
S-14 Oil Pressure Drops2085
S-15 Fuel Mixes Into Engine Oil2087
S-16 Water Mixes Into Engine Oil (Milky)2088
S-17 Coolant Temperature Increases Too High (Overheating)2089
S-18 Unusual Noise is Heard2090
S-19 Vibration is Excessive2091
S-20 Air Cannot be Bled from Fuel Circuit2092
S-21 Active Regeneration is Done Frequently2093
S-22 Active Regeneration Continues Long2095
S-23 White Smoke is Exhausted During Active Regeneration2096
S-24 DEF Consumption is Excessive2097
S-25 There is Unusual Smell (Irritating Odor)2099
S-26 Foreign Materials Enter DEF (DEF Increases)2100
50 Disassembly and Assembly2101
Table of Contents2102
Precautions Before Work2107
Related Information on Disassembly and Assembly2108
How to Read This Manual2108
Coating Materials List2109
Special Tool List2114
Sketches of Special Tools2129
Engine and Cooling System2137
Remove and Install Supply Pump Assembly2137
How to Remove Supply Pump Assembly2137
How to Install Supply Pump Assembly2142
Remove and Install Injector Assembly2150
How to Remove Injector Assembly2150
How to Install Injector Assembly2157
Remove and Install Cylinder Head Assembly2169
How to Remove Cylinder Head Assembly2170
How to Install Cylinder Head Assembly2179
Remove and Install EGR Valve Assembly2197
How to Remove EGR Valve Assembly2197
How to Install EGR Valve Assembly2198
Remove and Install EGR Cooler Assembly2200
How to Remove EGR Cooler Assembly2200
How to Install EGR Cooler Assembly2201
Remove and Install Starter Assembly2204
How to Remove Starting Motor Assembly2204
How to Install Starting Motor Assembly2205
Remove and Install Alternator Belt2206
How to Remove Alternator Belt2206
How to Install Alternator Belt2209
Remove and Install Radiator Assembly2212
How to Remove Radiator Assembly2212
How to Install Radiator Assembly2214
Remove and Install Hydraulic Oil Cooler Assembly2216
How to Remove Hydraulic Oil Cooler Assembly2216
How to Install Hydraulic Oil Cooler Assembly2218
Remove and Install Aftercooler Assembly2222
How to Remove Aftercooler Assembly2222
How to Install Aftercooler Assembly2223
Remove and Install Engine and Main Pump Assembly2225
How to Remove Engine and Main Pump Assembly2226
How to Install Engine and Main Pump Assembly2238
Remove and Install Engine Front Oil Seal2253
How to Remove Engine Front Oil Seal2253
How to Install Engine Front Oil Seal2257
Remove and Install Engine Rear Oil Seal2261
How to Remove Engine Rear Oil Seal2262
How to Install Engine Rear Oil Seal2263
Remove and Install Engine Hood Assembly2270
How to Remove Engine Hood Assembly2270
How to Install Engine Hood Assembly2271
Remove and Install Fuel Tank Assembly2274
How to Remove Fuel Tank Assembly2274
How to Install Fuel Tank Assembly2277
Remove and Install DEF Tank Assembly2280
How to Remove DEF Tank Assembly2280
How to Install DEF Tank Assembly2286
Remove and Install DEF Tank Sensor Flange Assembly2292
How to Remove DEF Tank Sensor Flange Assembly2292
How to Install DEF Tank Sensor Flange Assembly2299
Remove and Install DEF Tank Sensor2304
How to Remove DEF Tank Sensor2304
How to Install DEF Tank Sensor2304
Remove and Install DEF Tank Strainer2311
How to Remove DEF Tank Strainer2311
How to Install DEF Tank Strainer2311
Remove and Install DEF Tank Filler Port Filter2312
How to Remove DEF Tank Filler Port Filter2312
How to Install DEF Tank Filler Port Filter2314
Remove and Install KDPF Assembly2317
How to Remove KDPF Assembly2317
How to Install KDPF Assembly2320
Disassemble and Assemble KDPF Assembly2325
How to Disassemble KDPF Assembly2326
How to Assemble KDPF Assembly2329
Remove and Install SCR Assembly2334
How to Remove SCR Assembly2334
How to Install SCR Assembly2337
Remove and Install KDPF and SCR Assembly2340
How to Remove KDPF and SCR Assembly2341
How to Install KDPF and SCR Assembly2348
Remove and Install KDPF and SCR Assembly Bracket2355
How to Remove KDPF and SCR Assembly Bracket2355
How to Install KDPF and SCR Assembly Bracket2358
Remove and Install Bellows Pipe Assembly2363
How to Remove Bellows Pipe Assembly2363
How to Install Bellows Pipe Assembly2366
Remove and Install KCCV Assembly2370
How to Remove KCCV Assembly2370
How to Install KCCV Assembly2371
Remove and Install DEF Mixing Tube2373
How to Remove DEF Mixing Tube2374
How to Install DEF Mixing Tube2377
Remove and Install DEF Injector2381
How to Remove DEF Injector2381
How to Install DEF Injector2384
Remove and Install DEF Pump2388
How to Remove DEF Pump (Applicable Machine Model: 90156 to 92053)2388
How to Install DEF Pump (Applicable Machine Model: 90156 to 92053)2391
How to Remove DEF Pump (Applicable Machine Model: 92054 and up)2393
How to Install DEF Pump (Applicable Machine Model: 92054 and up)2396
Remove and Install DEF Hose2399
How to Remove DEF Hose (Applicable Machine Model: 90156 to 92053)2400
How to Install DEF Hose (Applicable Machine Model: 90156 to 92053)2406
How to Remove DEF Hose (Applicable Machine Model: 92054 and up)2413
How to Install DEF Hose (Applicable Machine Model: 92054 or Later)2420
Remove and Install Air Cleaner Assembly2428
How to Remove Air Cleaner Assembly2428
How to Install Air Cleaner Assembly2430
Remove and Install Air Conditioner Compressor Assembly2432
How to Remove Air Conditioner Compressor Assembly2432
How to Install Air Conditioner Compressor Assembly2433
Remove and Install Air Conditioner Condenser Assembly2435
How to Remove Air Conditioner Condenser Assembly2435
How to Install Air Conditioner Condenser Assembly2436
Power Train2437
Remove and Install Travel Motor and Final Drive Assembly2437
How to Remove Travel Motor and Final Drive Assembly2437
How to Install Travel Motor and Final Drive Assembly2438
Disassemble and Assemble Final Drive Assembly2440
How to Disassemble Final Drive Assembly2441
How to Assemble Final Drive Assembly2445
Remove and Install Swing Motor and Swing Machinery Assembly2453
How to Remove Swing Motor and Swing Machinery Assembly2453
How to Install Swing Motor and Swing Machinery Assembly2454
Disassemble and Assemble Swing Machinery Assembly2456
How to Disassemble Swing Machinery Assembly2456
How to Assemble Swing Machinery Assembly2459
Remove and Install Swing Circle Assembly2467
How to Remove Swing Circle Assembly2467
How to Install Swing Circle Assembly2467
Undercarriage and Frame2469
Separate and Connect Track Assembly2469
How to Separate Track Assembly2469
How to Install Track Assembly2471
Remove and Install Sprocket2474
How to Remove Sprocket2474
How to Install Sprocket2474
Remove and Install Idler and Idler Cushion Assembly2476
How to Remove Idler and Idler Cushion Assembly2476
How to Install Idler and Idler Cushion Assembly2477
Disassemble and Assemble Idler Assembly2478
How to Disassemble Idler Assembly2478
How to Assemble Idler Assembly2479
Disassemble and Assemble Idler Cushion Assembly2483
How to Disassemble Idler Cushion Assembly2484
How to Assemble Idler Cushion Assembly2484
Disassemble and Assemble Track Roller Assembly2486
How to Disassemble Track Roller Assembly2487
How to Assemble Track Roller Assembly2488
Disassemble and Assemble Carrier Roller Assembly2490
How to Disassemble Carrier Roller Assembly2490
How to Assemble Carrier Roller Assembly2491
Remove and Install Revolving Frame Assembly2494
How to Remove Revolving Frame Assembly2494
How to Install Revolving Frame Assembly2496
Remove and Install Counterweight Assembly2499
How to Remove Counterweight Assembly2499
How to Install Counterweight Assembly2500
Hydraulic System2503
Remove and Install Center Swivel Joint Assembly2503
How to Remove Center Swivel Joint Assembly2503
How to Install Center Swivel Joint Assembly2504
Disassemble and Assemble Center Swivel Joint Assembly2507
How to Disassemble Center Swivel Joint Assembly2508
How to Assemble Center Swivel Joint Assembly2509
Remove and Install Hydraulic Tank Assembly2510
How to Remove Hydraulic Tank Assembly2510
How to Install Hydraulic Tank Assembly2514
Remove and Install Main Pump Assembly2518
How to Remove Main Pump Assembly2518
How to Install Main Pump Assembly2521
Remove and Install Control Valve Assembly2524
How to Remove Control Valve Assembly2524
How to Install Control Valve Assembly2531
Disassemble and Assemble Control Valve Assembly2538
How to Replace Pressure Compensation Valve Seal Ring2539
How to Assemble Control Valve Assembly2540
Disassemble and Assemble Work Equipment PPC Valve Assembly2545
How to Disassemble Work Equipment PPC Valve Assembly2545
How to Assemble Work Equipment PPC Valve Assembly2546
Disassemble and Assemble Travel PPC Valve Assembly2548
How to Disassemble Travel PPC Valve Assembly2548
How to Assemble Travel PPC Valve Assembly2549
Work Equipment2551
Remove and Install Bucket Assembly2551
How to Remove Bucket Assembly2551
How to Install Bucket Assembly2551
Remove and Install Arm Assembly2553
How to Remove Arm Assembly2553
How to Install Arm Assembly2554
Remove and Install Work Equipment Assembly2556
How to Remove Work Equipment Assembly2556
How to Install Work Equipment Assembly2559
Remove and Install Boom Anti-drop Valve Assembly2562
How to Remove Boom Anti-drop Valve Assembly2562
How to Install Boom Anti-drop Valve Assembly2564
Remove and Install Arm Anti-Drop Valve Assembly2565
How to Remove Arm Anti-Drop Valve Assembly2565
How to Install Arm Anti-Drop Valve Assembly2567
Disassemble and Assemble Anti-Drop Valve Assembly2568
How to Disassemble Anti-Drop Valve Assembly2568
How to Assemble Anti-Drop Valve Assembly2568
Disassemble and Assemble Work Equipment Cylinder Assembly2569
How to Disassemble Work Equipment Cylinder Assembly2569
How to Assemble Work Equipment Cylinder Assembly2572
CAB Related Parts2579
Remove and Install Operator Cab Assembly2579
How to Remove Operator Cab Assembly2579
How to Install Operator Cab Assembly2587
Remove and Install Operator Cab Glass (Adhered Glass)2594
How to Remove Operator Cab Glass (Adhered Glass)2596
How to Install Operator Cab Glass (Adhered Glass)2596
Remove and Install Front Window Assembly2606
How to Remove Front Window Assembly2606
How to Install Front Window Assembly2609
Remove and Install Floor Frame Assembly2615
How to Remove Floor Frame Assembly2616
How to Install Floor Frame Assembly2622
Remove and Install Air Conditioner Unit Assembly2630
How to Remove Air Conditioner Unit Assembly2630
How to Install Air Conditioner Unit Assembly2635
Remove and Install Operator Seat2641
How to Remove Operator Seat2641
How to Install Operator Seat2643
How to Remove and Install Seat Belt2646
How to Remove Seat Belt2646
How to Install Seatbelt2647
Remove and Install Work Equipment Control Lever Assembly2648
How to Remove Work Equipment Control Lever Assembly2648
How to Install Work Equipment Control Lever Assembly2654
Remove and Install Front Wiper Assembly2663
How to Remove Front Wiper Assembly2663
How to Install Front Wiper Assembly2668
Electrical System2677
Remove and Install Engine Controller Assembly2677
How to Remove Engine Controller Assembly2677
How to Install Engine Controller Assembly2679
Remove and Install Pump Controller Assembly2683
How to Remove Pump Controller Assembly2683
How to Install Pump Controller Assembly2686
Remove and Install KomVision Controller Assembly2690
How to Remove KomVision Controller Assembly2690
How to Install KomVision Controller Assembly2691
Remove and Install Machine Monitor Assembly2692
How to Remove Machine Monitor Assembly2692
How to Install Machine Monitor Assembly2695
Remove and Install Pump Swash Plate Sensor2699
How to Remove Pump Swash Plate Sensor2699
How to Install Pump Swash Plate Sensor2699
Remove and Install Mass Air Flow and Temperature Sensor2701
How to Remove Mass Air Flow and Temperature Sensor2701
How to Install Mass Air Flow and Temperature Sensor2702
Remove and Install KCCV Crankcase Pressure Sensor2703
How to Remove KCCV Crankcase Pressure Sensor2703
How to Install KCCV Crankcase Pressure Sensor2704
Remove and Install SCR Temperature Sensor2705
How to Remove SCR Temperature Sensor2705
How to Install SCR Temperature Sensor2706
Remove and Install Rearview Camera2708
How to Remove Rearview Camera2708
How to Install Rearview Camera2709
Remove and Install KomVision Camera2711
How to Remove KomVision Camera2711
How to Install KomVision Camera2712
Remove and Install Gateway Function Controller Assembly2714
How to Remove Gateway Function Controller Assembly2714
How to Install Gateway Function Controller Assembly2719
Remove and Install Communication Terminal Wiring Harness2724
How to Remove Communication Terminal Wiring Harness2724
How to Install Communication Terminal Wiring Harness2732
Remove and Install Communication Terminal2741
How to Remove Communication Terminal2741
How to Install Communication Terminal2743
60 Maintenance Standard2747
Table of Contents2748
Engine and Cooling System2749
Maintenance Standard for Engine Mount2749
Maintenance Standard for Cooling System2751
Power Train2752
Maintenance Standard for Swing Circle2752
Maintenance Standard for Swing Machinery2753
Maintenance Standard for Final Drive2755
Maintenance Standard for Sprocket2757
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2758
Undercarriage and Frame2759
Maintenance Standard for Track Frame and Idler Cushion2759
Maintenance Standard for Idler2761
Maintenance Standard for Track Roller2763
Maintenance Standard for Carrier Roller2765
Maintenance Standard for Track Shoes2766
Maintenance Standard for Triple Shoes2769
Hydraulic System2770
Maintenance Standard for Hydraulic Tank2770
Maintenance Standard for Main Pump2771
Maintenance Standard for Swing Motor2773
Maintenance Standard for Travel Motor2776
Maintenance Standard for Control Valve2779
Maintenance Standard for Boom Anti-Drop Valve2789
Maintenance Standard for Arm Anti-Drop Valve2791
Maintenance Standard for Work Equipment and Swing PPC Valve2793
Maintenance Standard for Travel PPC Valve2796
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2799
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2800
Maintenance Standard for 2nd-Line Attachment PPC Valve2802
Maintenance Standard for Solenoid Valve2804
Maintenance Standard for Attachment Circuit Selector Valve2805
Maintenance Standard for Center Swivel Joint2806
Work Equipment2807
Maintenance Standard for Work Equipment Linkage2807
Dimensions of Arm2812
Dimensions of Bucket2814
Maintenance Standard for Boom Cylinder2816
Maintenance Standard for Arm Cylinder2817
Maintenance Standard for Bucket Cylinder2818
80 Appendix2819
Table of Contents2820
Precautions Before Work2822
Air Conditioner System2823
Precautions for Refrigerant2823
Air Conditioner Component2824
Specifications of Air Conditioner2826
Structure and Function of Refrigeration Cycle2827
Outline of Refrigeration Cycle2828
Component Parts of Air Conditioner System2830
Air Conditioner Unit2830
Configuration Diagram of Air Conditioner Unit2830
Function of Air Conditioner Unit2832
Component Parts of Air Conditioner Unit2834
Function of Evaporator as Air Conditioner Unit Component2835
Function of Heater Core as Air Conditioner Unit Component2835
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2835
Function of Servo Motor as Air Conditioner Unit Component2835
Structure of Expansion Valve as Air Conditioner Unit Component2836
Function of Expansion Valve as Air Conditioner Unit Component2836
Operate Expansion Valve as Air Conditioner Unit Component2836
Function of Dual Pressure Switch2837
Air Conditioner Controller2838
Structure of Air Conditioner Controller2838
Compressor2839
Structure of Compressor2839
Specifications of Compressor2839
Function of Compressor2839
Condenser2840
Structure of Condenser2840
Specifications of Condenser2840
Function of Condenser2840
Receiver Drier2841
Structure of Receiver Dryer2841
Specifications of Receiver Dryer2841
Function of Receiver Dryer2841
Air Conditioner Related Sensors2842
Structure of Sunlight Sensor2842
Function of Sunlight Sensor2842
Structure of Outside Temperature Sensor2842
Function of Outside Air Temperature Sensor2842
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2844
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2846
System Diagram of Air Conditioner2848
Input and Output Signals of Air Conditioner Controller2849
Function of Air Conditioner Controller2850
Locations of Air Conditioner Parts and Layout of Connectors2851
Examine Air Leakage (Duct)2855
How to Examine Air Leakage (Duct)2855
Examine Air Conditioner with Self-Diagnosis Function2857
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2858
Examine Vent (Mode) Changeover2859
How to Examine Vent (Mode) Changeover2859
Examine Fresh/Recirc Air Changeover2861
How to Examine Fresh/Recirc Air Changeover2861
Examine Sunlight Sensor2862
How to Examine Sunlight Sensor2862
Examine Refrigerant (Dual) Pressure Switch2863
How to Examine Refrigerant (Dual) Pressure Switch2863
Examine Relay2864
How to Examine Relay2864
Air Conditioner Troubleshooting Chart 12865
Air Conditioner Troubleshooting Chart 22866
Information Shown in Troubleshooting Table2869
Failure Code [879AKA]2870
Failure Code [879AKB]2871
Failure Code [879BKA]2872
Failure Code [879BKB]2874
Failure Code [879CKA]2876
Failure Code [879CKB]2877
Failure Code [879DKZ]2878
Failure Code [879EMC]2880
Failure Code [879FMC]2881
Failure Code [879GKX]2882
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2884
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2886
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2889
A-4 Troubleshooting for Fresh/Recirc Air Changeover2891
Troubleshooting by Gauge Pressure2893
Connect Service Tool2896
How to Connect Service Tool2896
Precautions for Disconnection and Connection of Air Conditioner Piping2898
Handle Compressor Oil2900
90 Circuit Diagrams2903
Table of Contents2904
Hydraulic Circuit Diagram2905
Symbols Used in Hydraulic Circuit Diagram2905
Hydraulic Circuit Diagram (1/3)2909
Hydraulic Circuit Diagram (2/3)2911
Hydraulic Circuit Diagram (3/3)2913
Electrical Circuit Diagram2915
Symbols Used in Electric Circuit Diagram2915
Electrical Circuit Diagram (1/12)2919
Electrical Circuit Diagram (2/12)2921
Electrical Circuit Diagram (3/12)2923
Electrical Circuit Diagram (4/12)2925
Electrical Circuit Diagram (5/12)2927
Electrical Circuit Diagram (6/12)2929
Electrical Circuit Diagram (7/12)2931
Electrical Circuit Diagram (8/12)2933
Electrical Circuit Diagram (9/12)2935
Electrical Circuit Diagram (10/12)2937
Electrical Circuit Diagram (11/12)2939
Electrical Circuit Diagram (12/12)2941
Index2943

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24