Komatsu HYDRAULIC EXCAVATOR PC360LC-11E0 Shop Manual SEN06956-02 PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC360LC-11E0 Shop Manual SEN06956-02 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11E0 Shop Manual SEN06956-02 – PDF DOWNLOAD

Language : English
Pages :2888
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11E0 Shop Manual SEN06956-02 – PDF DOWNLOAD

SERIAL NUMBERS 92143 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11E0 Shop Manual SEN06956-02 – PDF DOWNLOAD

SERIAL NUMBERS 92143 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
Actions Taken to Meet Exhaust Gas Regulations 38
How to Examine Engine Type 39
Precautions for DEF 41
General Character and Precautions for Handling 41
Precautions for Adding 41
Precautions for Storage 41
Precautions for Fire Hazard and Leakage 41
Other Precautions 41
Store DEF 42
Precautions When You Handle Hydraulic Equipment 43
Precautions When You Disconnect and Connect Pipings 46
Precautions When You Handle Electrical Equipment 53
Precautions When You Handle Fuel System Equipment 55
Precautions When You Handle Intake System Equipment 56
Practical Use of KOMTRAX 57
Disconnect and Connect Push-Pull Type Coupler 58
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 60
Precautions for Disconnection and Connection of Connectors 62
How to Disconnect and Connect Deutsch Connector 66
How to Disconnect and Connect Slide Lock Type Connector 67
How to Disconnect and Connect Connector with Lock to Pull 69
How to Disconnect and Connect Connector with Lock to Push 70
How to Disconnect and Connect Connector with Housing to Rotate 72
How to Read the Codes for Electric Cable 73
Explanation of Terms for Maintenance Standard 77
Standard Tightening Torque Table 80
Conversion Table 87
01 Specifications 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: PC360LC-11E0 95
Working Range Drawings 97
Working Range: PC360LC-11E0 97
Specifications 98
Specifications: PC360LC-11E0 98
Weight Table 101
Weight Table: PC360LC-11E0 101
Table of Fuel, Coolant, and Lubricants 103
10 Structure and Function 105
Table of Contents 106
Urea SCR System 110
Layout Drawing of Urea SCR System 110
Urea SCR System Diagram 114
Function of Urea SCR System 115
Function of DEF System 115
Inducement Strategy 117
Component Parts of Urea SCR System 135
DEF Mixing Tube 135
SCR Assembly 135
DEF Tank 138
DEF Pump 140
DEF Injector 141
DEF Hose 142
DEF Tank Heating Valve 143
Boot-up System 144
Layout Drawing of Boot-up System 144
System Operating Lamp System 146
System Diagram of System Operating Lamp 146
Function of Operation Lamp System 146
Battery Disconnect Switch 148
Function of Battery Disconnect Switch 148
Engine System 149
Layout Drawing of Engine System 149
Specifications of Engine System 150
Function of Engine System 150
Engine Control System 151
System Diagram of Engine Control 151
Operation of Engine Control System 152
Auto-Deceleration System 154
System Diagram of Auto-Deceleration System 154
Function of Auto-Deceleration System 154
Operation of Auto-Deceleration System 155
Engine Automatic Warm-up System 156
System Diagram of Engine Automatic Warm-up System 156
Function of Engine Automatic Warm-up System 157
Overheat Prevention System 158
Overheat Prevention System Diagram 158
Function of Overheat Prevention System 159
Turbocharger Protection System 160
System Diagram of Turbocharger Protection System 160
Function of Turbocharger Protection System 161
Automatic Idle Stop System 162
System Diagram of Automatic Idle Stop System 162
Function of Automatic Idle Stop System 162
Operation of Automatic Idle Stop System 162
Component Parts of Engine System 165
VGT 165
EGR System 168
EGR Valve 170
EGR Cooler 172
KCCV System 173
KCCV Ventilator 175
KDPF 176
Cooling System 181
Layout Drawing of Cooling System 181
Specifications of Cooling System 182
Control System 183
Layout Drawing of Control System 183
Machine Monitor System 186
Machine Monitor System Diagram 186
Function of Machine Monitor System 186
KomVision System 187
Layout Drawing of KomVision System 187
System Diagram of KomVision System 189
Function of KomVision System 189
KOMTRAX System 191
System Diagram of KOMTRAX System 191
Function of KOMTRAX System 191
Component Parts of Control System 192
Machine Monitor 192
KomVision Controller 206
KomVision Camera 210
KOMTRAX Terminal 211
Gateway Function Controller 213
Communication Terminal 216
Pump Controller 218
Resistor for PC-EPC Valve 222
CAN Terminating Resistor 222
PPC Oil Pressure Switch 223
Engine Controller 224
Fuel Control Dial 231
Sensor 233
Structure of Ambient Pressure Sensor 233
Function of Ambient Pressure Sensor 233
Structure of Engine Oil Pressure Switch 233
Function of Engine Oil Pressure Switch 234
Structure of Charge (Boost) Pressure and Temperature Sensor 234
Function of Charge (Boost) Pressure and Temperature Sensor 234
Structure of Coolant Temperature Sensor 235
Function of Coolant Temperature Sensor 235
Structure of NE (Crankshaft) Speed Sensor 235
Function of NE (Crankshaft) Speed Sensor 236
Structure of Bkup (Camshaft) Speed Sensor 236
Function of Bkup (Camshaft) Speed Sensor 236
Structure of Common Rail Pressure Sensor 237
Function of Common Rail Pressure Sensor 237
Structure of EGR Valve Lift Sensor 237
Function of EGR Valve Lift Sensor 237
Structure of VGT Speed Sensor 238
Function of KVGT Speed Sensor 238
Structure of KVGT Position Sensor 238
Function of KVGT Position Sensor 239
Structure of Mass Air Flow and Temperature Sensor 239
Structure of KDPF Differential Pressure and Outlet Pressure Sensor 240
Function of KDPF Differential Pressure and Outlet Pressure Sensor 240
Structure of Crankcase Pressure Sensor 240
Function of Crankcase Pressure Sensor 241
Structure of Engine Oil Level Sensor 241
Structure of Air Cleaner Clogging Sensor 241
Function of Air Cleaner Clogging Sensor 242
Structure of Water-in-Fuel Sensor 242
Function of Water-in-Fuel Sensor 242
Structure of Auto Grease Pressure Switch 243
Specifications – Auto Grease Pressure Switch 243
Function of Auto Grease Pressure Switch 243
Structure of Overload Caution Sensor 243
Specifications – Overload Caution Sensor 244
Function of Overload Caution Sensor 244
Hydraulic System 245
Layout Drawing of Hydraulic System 245
CLSS 248
Structure of CLSS 248
Operation of Unload Valve and LS Pressure 250
Pump Swash Plate Angle (Oil Flow) Control 251
Pressure Compensation Control 264
Engine and Pump Combined Control System 268
Engine and Pump Combined Control System Diagram 268
Function of Engine and Pump Combined Control System 269
Pump and Valve Control System 274
Pump and Valve Control System Diagram 274
Function of Pump and Valve Control System 275
Component Parts of Hydraulic System 277
Hydraulic Tank 277
Main Pump 280
Control Valve 306
Work Equipment System 364
Layout Drawing of Work Equipment System 364
Structure of Valve Control 370
One-Touch Power Maximizing System 372
System Diagram of One-Touch Power Maximizing System 372
Function of One-Touch Power Maximizing System 373
Machine Push-up System 374
Machine Push-up System Diagram 374
Function of Machine Push-up System 375
PPC Lock System 376
System Diagram of PPC Lock 376
Function of PPC Lock System 376
Work Equipment and Travel Automatic Lock System 377
System Diagram of Lock Lever Automatic Lock System 377
Function of Work Equipment and Travel Automatic Lock System 377
Operation of Lock Lever Automatic Lock System 378
Attachment Oil Flow Adjuster System 379
Attachment Oil Flow Adjuster System Diagram 379
Function of Attachment Oil Flow Adjuster System 380
Component Parts of Work Equipment System 381
Work Equipment and Swing PPC Valve 381
1st-Line Attachment PPC Valve (with EPC Valve) 386
2nd-Line Attachment PPC Valve 390
Solenoid Valve 392
Attachment Circuit Selector Valve 395
Pilot Circuit Accumulator 397
Swing System 399
Layout Drawing of Swing System 399
Swing Control System Diagram 402
Function of Swing Control System 402
Component Parts of Swing System 406
Swing Motor 406
Swing Machinery 417
Swing Circle 419
Travel System 420
Layout Drawing of Travel System 420
System Diagram of Travel Control System 424
Function of Travel Control System 424
Component Parts of Travel System 426
Travel Motor 426
Final Drive 438
Travel PPC Valve 439
Center Swivel Joint 444
Undercarriage and Frame 446
Layout Drawing of Undercarriage 446
Specifications of Undercarriage 446
Work Equipment 448
Structure of Work Equipment 448
Function of Work Equipment 449
Work Equipment Clearance Adjustment Shim 450
Function of Work Equipment Clearance Adjustment Shim 450
Bucket Clearance Adjustment Shim 451
Function of Bucket Clearance Adjustment Shim 451
CAB Related Parts 452
ROPS CAB 452
Structure of ROPS CAB 452
Function of ROPS CAB 452
CAB Mount 453
Structure of CAB Mount 453
Function of CAB Mount 453
CAB Tipping Stopper 454
Structure of CAB Tipping Stopper 454
Function of CAB Tipping Stopper 454
20 Standard Value Table 455
Table of Contents 456
Standard Value Table for Engine 457
Standard Value Table for Engine: PC360LC-11E0 457
Standard Value Table for Machine 462
Standard Value Table for Machine: PC360LC-11E0 462
Machine Posture and Procedures to Measure Performance 476
Standard Value Table for Electricity 480
Standard Value Table for Electricity 480
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 and Adjust Valve Clearance 511
How to Examine Valve Clearance 511
How to Adjust Valve Clearance 513
Examine Compression Pressure 514
How to Examine Compression Pressure 514
Examine Blowby Pressure 517
How to Examine Blowby Pressure 517
Examine Engine Oil Pressure 519
How to Examine Engine Oil Pressure 519
Examine EGR Valve and VGT Oil Pressure 521
How to Examine EGR Valve and VGT Oil Pressure 521
Examine Fuel Pressure 523
How to Examine Fuel Pressure 524
Examine Fuel Discharge, Return and Leakage 530
How to Examine Fuel Discharge, Return, and Leakage 531
Bleed Air from Fuel System 537
How to Bleed Air from Fuel System 537
Examine Fuel Circuit for Leakage 538
How to Examine Fuel System for Leakage 538
Handle Cylinder Cut-out Mode Operation 540
Handle No-Injection Cranking Operation 541
Examine and Adjust Air Conditioner Compressor Belt Tension 542
How to Examine Air Conditioner Compressor Belt Tension 542
How to Adjust Air Conditioner Compressor Belt Tension 542
How to Adjust Air Conditioner Compressor Belt 543
Examine Fan Belt and Alternator Belt 544
How to Examine Fan Belt and Alternator Belt 544
Write Correction for Ash in Soot Accumulation to Engine Controller 545
How to Write Correction for Ash in Soot Accumulation to Engine Controller 545
Examine SCR Related Functions 546
Examine DEF Pump Raised Pressure 549
Examine Injection Volume from DEF Injector 552
Examine DEF Line Heater Relay 1 556
Examine DEF Line Heater Relay 2 558
Examine DEF Pump Heater Relay 561
Examine DEF Tank Heater Valve 564
Examine SCR Denitration Efficiency 567
Clean DEF Tank 571
How to Clean DEF Tank 571
Examine Automatic Tensioner 575
How to Examine Automatic Tensioner 575
Power Train 576
Examine Swing Circle Bearing Clearance 576
How to Examine Swing Circle Bearing Clearance 576
Undercarriage and Frame 577
Examine and Adjust Track Tension 577
How to Examine Track Tension 577
How to Adjust Track Tension 577
Hydraulic System 579
Release Remained Pressure in Hydraulic Circuit 579
How to Release Remaining Pressure from Hydraulic Tank 579
How to Release Remained Pressure in Hydraulic Cylinder Circuit 579
How to Release Remained Pressure from Swing Motor Circuit 584
How to Release Remained Pressure from Travel Motor Circuit 584
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 585
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 586
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 594
Examine Oil Pressure of Control Circuit 597
How to Examine Oil Pressure in Control Circuit 597
Examine and adjust oil pressure in pump PC control circuit 599
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 599
Examine PC-EPC Valve Outlet Pressure 600
How to Adjust Oil Pressure in Pump PC Control Circuit 601
Examine and Adjust Oil Pressure in Pump LS Control Circuit 602
How to Examine LS Differential Pressure with Machine Monitor 602
How to Examine LS Differential Pressure by Testing Tool 603
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 605
How to Examine LS-EPC Valve Outlet Pressure 605
How to Adjust LS Valve 606
Examine Outlet Pressure of Solenoid Valve 607
How to Examine Outlet Pressure of Solenoid Valve 607
Operating Condition of Solenoid Valve 608
Examine PPC Valve Outlet Pressure 610
How to Examine Outlet Pressure in PPC Valve 610
Adjust Play of Work Equipment and Swing PPC Valves 612
How to Adjust Play of Work Equipment and Swing PPC Valves 612
Release Remained Pressure in Hydraulic Circuit 613
Examine Pump Swash Plate Sensor 614
How to Examine pump swash plate sensor 614
Examine Parts Which Cause Hydraulic Drift of Work Equipment 615
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 615
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 615
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 616
Examine Oil Leakage 617
How to Examine Oil Leakage from Boom Cylinder 617
How to Examine Oil Leakage from Arm Cylinder 617
How to Examine Oil Leakage from Bucket Cylinder 618
How to Examine Oil Leakage from Swing Motor 618
How to Examine Oil Leakage from Travel Motor 619
Bleed Air from Hydraulic System 620
How to Bleed Air from Hydraulic System 622
CAB Related Parts 625
Examine CAB Tipping Stopper 625
How to Examine Cab Tipping Stopper 625
How to Adjust Mirrors 626
Procedure to Adjust Machine Left Front Mirror (A) 626
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 627
Procedure to Adjust Machine Right Front Mirror (B) 628
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 629
Procedure to Adjust Machine Right Side Mirror (C) 630
Electrical System 632
Set and Operate Machine Monitor 632
Operator Mode 635
Function to Show Technician Identification Status Screen 636
Function to Show Operator Identification Input Screen 636
Examine Function by LCD (Liquid Crystal Display) 637
Examine Function of Service Meter 637
Usage Limitation and Maintenance Password Change Function 637
Service Mode 640
How to See Pre-defined Monitoring Information 642
How to Examine Self-Define Monitor Information 649
Abnormality Record Menu 660
How to See Maintenance Record 665
Maintenance Mode Setting 666
How to Set Phone Number Entry 670
Default Menu 671
Diagnostic Tests Menu 679
Adjustment Menu 689
No-Injection Cranking Operation 706
KOMTRAX Settings Menu 707
How to Show Service Message 710
How to Start Up KOMTRAX System 712
How to Stop Use of KOMTRAX System 718
Adjust Rearview Camera Angle 720
How to Adjust Rearview Camera Angle 720
Adjust KomVision Camera Angle 723
How to Adjust KomVision Camera Angle 724
Adjust KomVision Related Function 728
Setting of KomVision (Main Setting) 728
Setting of KomVision (Camera Setting) 730
Setting of KomVision (Camera Calibration) 731
KomVision screen – Check 12 m visibility 744
Handle Voltage Circuit of Engine Controller 747
Handle Battery Disconnect Switch 748
Examine Diodes 749
How to Examine Diodes by Digital Tester 749
How to Examine Diodes by Analog Tester 749
Pm Clinic 750
Pm Clinic Service 750
Pm Clinic Check Sheet 751
40 Troubleshooting 765
Table of Contents 766
Precautions Before Work 777
Related Information to Troubleshooting 778
General Troubleshooting Points 778
Troubleshooting Points for Urea SCR System 779
Sequence of Events in Troubleshooting 791
Checks Before Troubleshooting 793
Inspection Procedure Before Troubleshooting 795
Walk-Around Check 795
Test in Accordance with Testing Procedure 797
Examine Fuel Level and Type 797
Examine for Impure Ingredient in Fuel 797
Examine Fuel Prefilter 798
Examine Water Separator, Drain Water and Sediment 798
How to Replace Fuel Prefilter Cartridge 799
Examine Fuel Main Filter 800
Examine Engine Oil Level (Oil Quantity in Oil Pan) 802
Examine Coolant Level (Reservoir Tank) 803
Examine Air Cleaner Clogging 804
Clean Outer Element 804
Replace Element 806
Examine Hydraulic Oil Level 807
Examine Hydraulic Oil Strainer 808
Examine Hydraulic Oil Filter 809
Examine Oil Level in Swing Machinery Case 810
Examine Oil Level in Damper Case 810
Examine Oil Level in Final Drive Case 811
Bleed Air from Fuel System 811
Bleed Air from Hydraulic System 811
How to Examine Electric Equipment 812
Preparation for Troubleshooting of Electrical System 817
Procedure for Troubleshooting 830
Symptom and Troubleshooting Numbers 833
Information Shown in Troubleshooting Table 837
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 839
Connector List and Layout 842
Connector Contact Connection Table 857
T-Branch Box and T-Branch Adapter Table 897
Fuse Location Table 903
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 906
Failure Code Table 910
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 929
Troubleshooting by Failure Code (Display of Code) 931
Failure Code [879AKA] 931
Failure Code [879AKB] 932
Failure Code [879BKA] 933
Failure Code [879BKB] 935
Failure Code [879CKA] 937
Failure Code [879CKB] 938
Failure Code [879DKZ] 939
Failure Code [879EMC] 941
Failure Code [879FMC] 942
Failure Code [879GKX] 943
Failure Code [989L00] 945
Failure Code [989M00] 946
Failure Code [989N00] 947
Failure Code [A1U0N3] 948
Failure Code [A1U0N4] 950
Failure Code [A900FR] 952
Failure Code [A900N6] 953
Failure Code [A900NY] 954
Failure Code [AA10NX] 955
Failure Code [AB00KE] 957
Failure Code [AQ10N3] 960
Failure Code [AS00N3] 962
Failure Code [AS00R2] 964
Failure Code [AS00R3] 965
Failure Code [AS00R4] 966
Failure Code [AS00R5] 967
Failure Code [AS00R6] 968
Failure Code [AS00ZK] 969
Failure Code [AS10KM] 970
Failure Code [AS10NR] 971
Failure Code [AS10NT] 972
Failure Code [B@BAZG] 973
Failure Code [B@BAZK] 974
Failure Code [B@BCNS] 976
Failure Code [B@BCQA] 977
Failure Code [B@BCZK] 979
Failure Code [B@HANS] 981
Failure Code [CA115] 982
Failure Code [CA122] 983
Failure Code [CA123] 985
Failure Code [CA131] 987
Failure Code [CA132] 989
Failure Code [CA144] 991
Failure Code [CA145] 993
Failure Code [CA153] 995
Failure Code [CA154] 998
Failure Code [CA187]1001
Failure Code [CA221]1003
Failure Code [CA222]1005
Failure Code [CA227]1007
Failure Code [CA234]1008
Failure Code [CA238]1009
Failure Code [CA239]1011
Failure Code [CA249]1013
Failure Code [CA256]1015
Failure Code [CA271]1017
Failure Code [CA272]1019
Failure Code [CA281]1021
Failure Code [CA322]1022
Failure Code [CA323]1024
Failure Code [CA324]1026
Failure Code [CA325]1028
Failure Code [CA331]1030
Failure Code [CA332]1032
Failure Code [CA343]1034
Failure Code [CA351]1035
Failure Code [CA352]1036
Failure Code [CA356]1039
Failure Code [CA357]1041
Failure Code [CA386]1043
Failure Code [CA428]1044
Failure Code [CA429]1046
Failure Code [CA435]1048
Failure Code [CA441]1050
Failure Code [CA442]1052
Failure Code [CA449]1053
Failure Code [CA451]1057
Failure Code [CA452]1060
Failure Code [CA488]1062
Failure Code [CA515]1063
Failure Code [CA516]1065
Failure Code [CA553]1067
Failure Code [CA555]1068
Failure Code [CA556]1069
Failure Code [CA559]1070
Failure Code [CA595]1074
Failure Code [CA687]1075
Failure Code [CA689]1077
Failure Code [CA691]1082
Failure Code [CA692]1084
Failure Code [CA697]1086
Failure Code [CA698]1087
Failure Code [CA731]1088
Failure Code [CA778]1090
Failure Code [CA1777]1095
Failure Code [CA1664]1098
Failure Code [CA1669]1100
Failure Code [CA1673]1101
Failure Code [CA1677]1102
Failure Code [CA1678]1103
Failure Code [CA1682]1104
Failure Code [CA1683]1106
Failure Code [CA1684]1108
Failure Code [CA1686]1110
Failure Code [CA1691]1111
Failure Code [CA1694]1114
Failure Code [CA1695]1117
Failure Code [CA1696]1118
Failure Code [CA1712]1120
Failure Code [CA1713]1123
Failure Code [CA1714]1125
Failure Code [CA1715]1126
Failure Code [CA1776]1127
Failure Code [CA1777]1130
Failure Code [CA1843]1133
Failure Code [CA1844]1135
Failure Code [CA1879]1138
Failure Code [CA1881]1141
Failure Code [CA1883]1143
Failure Code [CA1885]1146
Failure Code [CA1887]1148
Failure Code [CA1921]1150
Failure Code [CA1922]1153
Failure Code [CA1942]1158
Failure Code [CA1993]1159
Failure Code [CA2185]1162
Failure Code [CA2186]1164
Failure Code [CA2249]1166
Failure Code [CA2265]1167
Failure Code [CA2266]1169
Failure Code [CA2271]1171
Failure Code [CA2272]1174
Failure Code [CA2288]1177
Failure Code [CA2311]1178
Failure Code [CA2349]1179
Failure Code [CA2353]1182
Failure Code [CA2357]1184
Failure Code [CA2381]1185
Failure Code [CA2382]1188
Failure Code [CA2383]1191
Failure Code [CA2386]1194
Failure Code [CA2387]1196
Failure Code [CA2555]1197
Failure Code [CA2556]1199
Failure Code [CA2637]1201
Failure Code [CA2639]1203
Failure Code [CA2771]1206
Failure Code [CA2777]1212
Failure Code [CA2976]1215
Failure Code [CA3133]1217
Failure Code [CA3134]1219
Failure Code [CA3135]1221
Failure Code [CA3142]1224
Failure Code [CA3143]1225
Failure Code [CA3144]1226
Failure Code [CA3146]1228
Failure Code [CA3147]1229
Failure Code [CA3148]1230
Failure Code [CA3151]1232
Failure Code [CA3165]1238
Failure Code [CA3229]1240
Failure Code [CA3231]1242
Failure Code [CA3232]1244
Failure Code [CA3235]1248
Failure Code [CA3239]1250
Failure Code [CA3241]1253
Failure Code [CA3242]1256
Failure Code [CA3251]1259
Failure Code [CA3253]1261
Failure Code [CA3254]1264
Failure Code [CA3255]1267
Failure Code [CA3256]1271
Failure Code [CA3311]1273
Failure Code [CA3312]1275
Failure Code [CA3313]1278
Failure Code [CA3314]1279
Failure Code [CA3315]1280
Failure Code [CA3316]1282
Failure Code [CA3317]1283
Failure Code [CA3318]1284
Failure Code [CA3319]1286
Failure Code [CA3321]1287
Failure Code [CA3322]1289
Failure Code [CA3419]1291
Failure Code [CA3421]1293
Failure Code [CA3497]1295
Failure Code [CA3498]1296
Failure Code [CA3543]1297
Failure Code [CA3545]1304
Failure Code [CA3547]1306
Failure Code [CA3558]1307
Failure Code [CA3559]1309
Failure Code [CA3562]1311
Failure Code [CA3563]1313
Failure Code [CA3567]1316
Failure Code [CA3568]1319
Failure Code [CA3571]1323
Failure Code [CA3572]1325
Failure Code [CA3574]1327
Failure Code [CA3575]1329
Failure Code [CA3577]1331
Failure Code [CA3578]1333
Failure Code [CA3582]1335
Failure Code [CA3583]1341
Failure Code [CA3596]1343
Failure Code [CA3649]1345
Failure Code [CA3681]1347
Failure Code [CA3682]1352
Failure Code [CA3713]1358
Failure Code [CA3717]1361
Failure Code [CA3718]1362
Failure Code [CA3725]1363
Failure Code [CA3741]1366
Failure Code [CA3748]1367
Failure Code [CA3751]1369
Failure Code [CA3755]1371
Failure Code [CA3866]1373
Failure Code [CA3867]1377
Failure Code [CA3868]1380
Failure Code [CA3899]1384
Failure Code [CA3911]1386
Failure Code [CA3912]1390
Failure Code [CA3932]1392
Failure Code [CA3933]1394
Failure Code [CA3934]1396
Failure Code [CA3935]1399
Failure Code [CA3936]1401
Failure Code [CA4151]1403
Failure Code [CA4152]1407
Failure Code [CA4155]1411
Failure Code [CA4156]1413
Failure Code [CA4157]1415
Failure Code [CA4158]1417
Failure Code [CA4159]1418
Failure Code [CA4161]1419
Failure Code [CA4162]1422
Failure Code [CA4163]1425
Failure Code [CA4164]1427
Failure Code [CA4165]1429
Failure Code [CA4166]1431
Failure Code [CA4168]1433
Failure Code [CA4169]1436
Failure Code [CA4171]1438
Failure Code [CA4249]1441
Failure Code [CA4251]1443
Failure Code [CA4259]1445
Failure Code [CA4261]1448
Failure Code [CA4277]1451
Failure Code [CA4281]1455
Failure Code [CA4459]1458
Failure Code [CA4461]1460
Failure Code [CA4658]1463
Failure Code [CA4731]1467
Failure Code [CA4732]1468
Failure Code [CA4739]1469
Failure Code [CA4768]1470
Failure Code [CA4769]1472
Failure Code [CA4842]1475
Failure Code [CA4952]1479
Failure Code [CA5115]1481
Failure Code [CA5179]1484
Failure Code [CA5181]1486
Failure Code [CA5383]1488
Failure Code [D110KB]1490
Failure Code [D19JKZ]1492
Failure Code [D811MC]1495
Failure Code [D862KA]1496
Failure Code [D8ALKA]1498
Failure Code [D8ALKB]1501
Failure Code [D8AQKR]1503
Failure Code [D8G1KT]1510
Failure Code [D8G6KT]1511
Failure Code [DA20MC]1512
Failure Code [DA22KK]1513
Failure Code [DA25KP]1516
Failure Code [DA29KQ]1519
Failure Code [DA2LKA]1521
Failure Code [DA2LKB]1524
Failure Code [DA2QKR]1526
Failure Code [DA2RKR]1535
Failure Code [DAF0KM]1536
Failure Code [DAF0MB]1537
Failure Code [DAF0MC]1538
Failure Code [DAF8KB]1539
Failure Code [DAF9KQ]1541
Failure Code [DAFGMC]1542
Failure Code [DAFLKA]1543
Failure Code [DAFLKB]1546
Failure Code [DAFQKR]1548
Failure Code [DAZ9KQ]1556
Failure Code [DAZQKR]1557
Failure Code [DBPQKR]1564
Failure Code [DBP0KM]1572
Failure Code [DBP0KT]1573
Failure Code [DBP5KB]1574
Failure Code [DBP5KY]1577
Failure Code [DB2QKR]1580
Failure Code [DB2RKR]1589
Failure Code [DDNRKA]1594
Failure Code [DDNRKY]1596
Failure Code [DDNS00]1598
Failure Code [DGH2KB]1600
Failure Code [DHA4KA]1602
Failure Code [DHAAMA]1604
Failure Code [DHACMA]1606
Failure Code [DHPAMA]1608
Failure Code [DHPBMA]1611
Failure Code [DHS3MA]1614
Failure Code [DHS4MA]1617
Failure Code [DHS8MA]1620
Failure Code [DHS9MA]1623
Failure Code [DHSAMA]1626
Failure Code [DHSBMA]1629
Failure Code [DHSCMA]1632
Failure Code [DHSDMA]1635
Failure Code [DHSFMA]1638
Failure Code [DHSGMA]1641
Failure Code [DHSHMA]1644
Failure Code [DHSJMA]1647
Failure Code [DHZAMA]1650
Failure Code [DHZCL8]1654
Failure Code [DKR0MA]1655
Failure Code [DKR1MA]1658
Failure Code [DKULKA]1661
Failure Code [DKULKB]1663
Failure Code [DKULKY]1665
Failure Code [DR10KA]1667
Failure Code [DR12KA]1670
Failure Code [DR20KA]1672
Failure Code [DR21KX]1674
Failure Code [DR30KA]1676
Failure Code [DR31KX]1678
Failure Code [DR40KA]1680
Failure Code [DUMBKA]1682
Failure Code [DUMBKB]1685
Failure Code [DV00KA]1687
Failure Code [DV00KB]1688
Failure Code [DV20KB]1689
Failure Code [DW43KA]1691
Failure Code [DW43KB]1693
Failure Code [DW43KY]1695
Failure Code [DW45KA]1697
Failure Code [DW45KB]1700
Failure Code [DW45KY]1703
Failure Code [DW4CKY]1705
Failure Code [DW91KA]1706
Failure Code [DW91KB]1708
Failure Code [DW91KY]1710
Failure Code [DWA2KA]1712
Failure Code [DWA2KB]1714
Failure Code [DWA2KY]1716
Failure Code [DWK0KA]1718
Failure Code [DWK0KB]1720
Failure Code [DWK0KY]1722
Failure Code [DWK2KA]1724
Failure Code [DWK2KB]1726
Failure Code [DWK2KY]1728
Failure Code [DWK8KA]1730
Failure Code [DWK8KB]1732
Failure Code [DWK8KY]1734
Failure Code [DWPUKA]1736
Failure Code [DWPUKB]1738
Failure Code [DWPUKY]1740
Failure Code [DXA8KA]1742
Failure Code [DXA8KB]1745
Failure Code [DXA9KA]1747
Failure Code [DXA9KB]1750
Failure Code [DXE0KA]1752
Failure Code [DXE0KB]1754
Failure Code [DXE4KA]1756
Failure Code [DXE4KB]1758
Failure Code [DXE4KY]1760
Failure Code [DXE5KA]1761
Failure Code [DXE5KB]1763
Failure Code [DXE6KA]1765
Failure Code [DXE6KB]1767
Failure Code [DXE7KA]1769
Failure Code [DXE7KB]1771
Failure Code [DXE7KY]1773
Failure Code [DXE8KA]1775
Failure Code [DXE8KB]1777
Failure Code [DXE8KY]1779
Failure Code [DXE9KA]1781
Failure Code [DXE9KB]1783
Failure Code [DXE9KY]1785
Failure Code [DXEAKA]1787
Failure Code [DXEAKB]1789
Failure Code [DXEAKY]1791
Failure Code [DXEKKA]1793
Failure Code [DXEKKB]1795
Failure Code [DXEKKY]1797
Failure Code [DXELKA]1799
Failure Code [DXELKB]1801
Failure Code [DXELKY]1803
Failure Code [DY20KA]1805
Failure Code [DY20MA]1808
Failure Code [DY2CKB]1810
Failure Code [DY2DKB]1813
Failure Code [DY2EKB]1815
Failure Code [F311KA]1817
Failure Code [F311KB]1819
Failure Code [F312KA]1821
Failure Code [F312KB]1823
Failure Code [F313KA]1825
Failure Code [F313KB]1827
Failure Code [F314KA]1830
Failure Code [F314KB]1832
Failure Code [F315KB]1834
Failure Code [F315KY]1836
Failure Code [F316KB]1838
Failure Code [F316KY]1840
Failure Code [F318KB]1842
Failure Code [F318KY]1845
Failure Code [F31AKB]1847
Failure Code [F31AKY]1849
Failure Code [F31BKB]1851
Failure Code [F31BKY]1853
Failure Code [F31CKB]1855
Failure Code [F31CKY]1857
Failure Code [F31DKB]1859
Failure Code [F31DKY]1861
Failure Code [F31EKB]1863
Failure Code [F31EKY]1865
Troubleshooting of Electrical System (E-Mode)1867
E-1 Engine Does Not Start (Engine Does Not Crank)1867
E-2 Manual Preheating System Does Not Work1873
E-3 Automatic Preheating System Does Not Work1876
E-4 While Preheating Works, Preheating Monitor Does Not Come On1878
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing1880
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1883
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1884
E-8 Engine Coolant Temperature Monitor Comes On in White While Engine is Running1885
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine is Running1886
E-10 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running1887
E-11 Charge Level Monitor Lights Up in Red While Engine is Running1888
E-12 Fuel Level Monitor Comes On in Red While Engine is Running1889
E-13 Water Separator Monitor Comes On in Red While Engine is Running1890
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is Running1891
E-15 Engine Oil Pressure Monitor Comes On in Red While Engine is Running1892
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is Running1893
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1894
E-18 Display of Fuel Gauge Differs from Actual Fuel Level1896
E-19 Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1897
E-20 Display of Engine Coolant Temperature Gauge Differs from Actual Coolant Temperature1898
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1899
E-22 Display of Hydraulic Oil Temperature Gauge Differs from Actual Oil Temperature1901
E-23 Some Areas of Machine Monitor Screen are Not Displayed1902
E-24 Function Switch Does Not Operate1903
E-25 Automatic Warm-Up System Does Not Work (in Cold Weather)1904
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Off1905
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1906
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Displayed1907
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1908
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1909
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1910
E-32 Alarm Buzzer Cannot be Canceled1912
E-33 Service Meter is Not Displayed, While Starting Switch is in OFF Position1913
E-34 Service Mode Cannot be Selected1914
E-35 All of Work Equipments, Swing, and Travel Mechanism Do Not Move1915
E-36 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock1917
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1918
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1921
E-39 One-Touch Power Maximizing Function Does Not Operate Properly, or Indicator Not Displayed on Monitor1923
E-40 One-Touch Power Maximizing Function is Not Cancelled1925
E-41 Alarm Does Not Sound During Travel1926
E-42 Alarm Does Not Stop Sounding While Machine is Stopped1928
E-43 Horn Does Not Sound1929
E-44 Horn Does Not Stop Sounding1933
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Off1935
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1936
E-47 When Window Washer Switch is Operated, Window Washer Does Not Operate1938
E-48 Boom Raise Indicator is Not Displayed Properly with Monitoring Function1939
E-49 Boom Lower Indicator is Not Displayed Properly with Monitoring Function1940
E-50 Arm Out Indicator is Not Displayed Properly with Monitoring Function1941
E-51 Arm in Indicator is Not Displayed Properly with Monitoring Function1942
E-52 Bucket Dump Indicator is Not Displayed Properly with Monitoring Function1943
E-53 Bucket Curl Indicator is Not Displayed Properly with Monitoring Function1944
E-54 Swing Indicator is Not Displayed Properly with Monitoring Function1945
E-55 Travel Indicator is Not Displayed Properly with Monitoring Function1946
E-56 Service Indicator is Not Displayed Properly with Monitoring Function1947
E-57 Attachment Hydraulic Circuit Cannot be Changed1949
E-58 KOMTRAX System Does Not Operate Normally1950
R-55 Machine Push-Up Function is Not Canceled1951
E-60 Machine Push-Up Function Does Not Operate1953
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1954
Information Shown in Troubleshooting Table (H-Mode)1954
System Chart of Hydraulic and Mechanical Systems1955
Failure Mode and Cause Table1957
H-1 All Work Equipment, Swing and Travel Do Not Work1968
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1969
H-3 Fine Control Performance or Response is Poor1972
H-4 Unusual Noise is Heard from Around Hydraulic Pump1973
H-5 Engine Speed Drops Largely or Engine Stops1974
H-6 Speed or Power of Boom is Low1976
H-7 Arm Speed or Power is Low1982
H-8 Bucket Speed or Power is Low1987
H-9 Work Equipment Does Not Move in Single Operation1991
H-10 Hydraulic Drift of Boom is Large1992
H-11 Hydraulic Drift of Arm is Large1994
H-12 Hydraulic Drift of Bucket is Large1996
H-13 When Single Work Equipment is Relieved Hydraulically, Other Work Equipment Moves1997
H-14 Time Lag of Work Equipment is Large1998
H-15 One-Touch Power Maximizing Function Does Not Operate1999
H-16 Machine Push-Up Function Does Not Operate2000
H-17 Attachment Circuit Cannot be Changed2001
H-18 Oil Flow in Attachment Circuit Cannot be Changed2002
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower2003
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely2004
H-21 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low2005
H-22 Machine Does Not Travel Straight2006
H-23 Machine is Not Steered Correctly or Steering Power is Low2008
H-24 Travel Speed is Low2011
H-25 One of Tracks Does Not Run2013
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2015
H-27 Machine Does Not Swing to Right or Left2016
H-28 Upper Structure Swings Only to Right or Left2017
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left2018
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction2019
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2020
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2021
H-33 Shock is Large When Upper Structure Stops Swing Operation2022
H-34 Large Unusual Noise is Heard When Upper Structure Stops Swinging2023
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2024
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2025
Troubleshooting of Engine (S-Mode)2026
Information Shown in Troubleshooting Table (S-Mode)2026
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position2027
S-2 Engine Cranks but No Exhaust Gas Comes Out2028
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2029
S-4 Engine Startability is Unsatisfactory2031
S-5 Engine Does Not Pick Up Smoothly2033
S-6 Engine Stops During Operation2035
S-7 Engine Runs Rough or is Not Stable2037
S-8 Engine Lacks Power2038
S-9 KDPF Becomes Clogged in a Short Time2040
S-10 Engine Oil Consumption is Excessive2042
S-11 Oil Becomes Dirty Quickly2043
S-12 Fuel Consumption is Excessive2044
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)2045
S-14 Oil Pressure Drops2046
S-15 Fuel Mixes Into Engine Oil2048
S-16 Water Mixes Into Engine Oil (Milky)2049
S-17 Coolant Temperature Rises Too High (Overheating)2050
S-18 Unusual Noise is Heard2051
S-19 Vibration is Excessive2052
S-20 Air Cannot be Bled from Fuel Circuit2053
S-21 Active Regeneration is Executed Frequently2054
S-22 Active Regeneration Continues Long2056
S-23 White Smoke is Exhausted During Active Regeneration2057
S-24 DEF Consumption is Excessive2058
S-25 There is Unusual Smell (Irritating Odor)2060
S-26 Foreign Materials Enter DEF (DEF Increases)2061
Troubleshooting of Working Range Indicator by Failure Code (if Equipped)2062
20 Supply Voltage > 32VDC2062
21 Supply Voltage < 12VDC2063
25 File Error Factory Setings2064
26 File Error User Setings2065
27 File Error Input Data2066
30 Proximity Switches Difference2067
86 Angle Sensor A2 Timeout2068
96 Angle Sensor A3/A5 Timeout2069
106 Angle Sensor A4/A6 Timeout2070
116 Angle Sensor Pitch Timeout2071
126 Angle Sensor Roll Timeout2072
50 Disassembly and Assembly2073
Table of Contents2074
Precautions Before Work2079
Related Information on Disassembly and Assembly2080
How to Read This Manual2080
Coating Materials List2081
Special Tool List2086
Sketches of Special Tools2101
Engine and Cooling System2109
Remove and Install Supply Pump Assembly2109
How to Remove Supply Pump Assembly2109
How to Install Supply Pump Assembly2114
Remove and Install Injector Assembly2122
How to Remove Injector Assembly2122
How to Install Injector Assembly2129
Remove and Install Cylinder Head Assembly2141
How to Remove Cylinder Head Assembly2141
How to Install Cylinder Head Assembly2150
Remove and Install EGR Valve Assembly2168
How to Remove EGR Valve Assembly2168
How to Install EGR Valve Assembly2169
Remove and Install EGR Cooler Assembly2171
How to Remove EGR Cooler Assembly2171
How to Install EGR Cooler Assembly2172
Remove and Install Starter Assembly2175
How to Remove Starting Motor Assembly2175
How to Install Starting Motor Assembly2176
Remove and Install Alternator Belt2177
How to Remove Alternator Belt2177
How to Install Alternator Belt2180
Remove and Install Radiator Assembly2183
How to Remove Radiator Assembly2183
How to Install Radiator Assembly2185
Remove and Install Hydraulic Oil Cooler Assembly2187
How to Remove Hydraulic Oil Cooler Assembly2187
How to Install Hydraulic Oil Cooler Assembly2189
Remove and Install Aftercooler Assembly2193
How to Remove Aftercooler Assembly2193
How to Install Aftercooler Assembly2194
Remove and Install Engine and Main Pump Assembly2196
How to Remove Engine and Main Pump Assembly2197
How to Install Engine and Main Pump Assembly2209
Remove and Install Engine Front Oil Seal2224
How to Remove Engine Front Oil Seal2224
How to Install Engine Front Oil Seal2228
Remove and Install Engine Rear Oil Seal2232
How to Remove Engine Rear Oil Seal2233
How to Install Engine Rear Oil Seal2234
Remove and Install Engine Hood Assembly2241
How to Remove Engine Hood Assembly2241
How to Install Engine Hood Assembly2242
Remove and Install Fuel Tank Assembly2245
Remove Fuel Tank Assembly2245
Install Fuel Tank Assembly2249
Remove and Install DEF Tank Assembly2253
How to Remove DEF Tank Assembly2253
How to Install DEF Tank Assembly2259
Remove and Install DEF Tank Sensor Flange Assembly2265
How to Remove DEF Tank Sensor Flange Assembly2265
How to Install DEF Tank Sensor Flange Assembly2272
Remove and Install DEF Tank Sensor2277
How to Remove DEF Tank Sensor2277
How to Install DEF Tank Sensor2277
Remove and Install DEF Tank Strainer2284
How to Remove DEF Tank Strainer2284
How to Install DEF Tank Strainer2284
Remove and Install DEF Tank Filler Port Filter2285
How to Remove DEF Tank Filler Port Filter2285
How to Install DEF Tank Filler Port Filter2287
Remove and Install KDPF Assembly2290
How to Remove KDPF Assembly2290
How to Install KDPF Assembly2293
Disassemble and Assemble KDPF Assembly2298
How to Disassemble KDPF Assembly2299
How to Assemble KDPF Assembly2302
Remove and Install SCR Assembly2307
How to Remove SCR Assembly2307
How to Install SCR Assembly2310
Remove and Install KDPF and SCR Assembly2313
How to Remove KDPF and SCR Assembly2314
How to Install KDPF and SCR Assembly2321
Remove and Install KDPF and SCR Assembly Bracket2328
How to Remove KDPF and SCR Assembly Bracket2328
How to Install KDPF and SCR Assembly Bracket2331
Remove and Install KCCV Assembly2336
How to Remove KCCV Assembly2336
How to Install KCCV Assembly2337
Remove and Install DEF Mixing Tube2339
How to Remove DEF Mixing Tube2340
How to Install DEF Mixing Tube2343
Remove and Install DEF Injector2347
Remove DEF Injector2347
Install DEF Injector2350
Remove and Install DEF Pump2354
Remove DEF Pump2354
Install DEF Pump2357
Remove and Install DEF Hose2359
Remove DEF Hose2360
Install DEF Hose2366
Remove and Install Air Cleaner Assembly2374
How to Remove Air Cleaner Assembly2374
How to Install Air Cleaner Assembly2376
Remove and Install Air Conditioner Compressor Assembly2378
How to Remove Air Conditioner Compressor Assembly2378
How to Install Air Conditioner Compressor Assembly2379
Remove and Install Air Conditioner Condenser Assembly2381
How to Remove Air Conditioner Condenser Assembly2381
How to Install Air Conditioner Condenser Assembly2382
Power Train2383
Remove and Install Travel Motor and Final Drive Assembly2383
How to Remove Travel Motor and Final Drive Assembly2383
How to Install Travel Motor and Final Drive Assembly2384
Disassemble and Assemble Final Drive Assembly2386
How to Disassemble Final Drive Assembly2387
How to Assemble Final Drive Assembly2391
Remove and Install Swing Motor and Swing Machinery Assembly2399
How to Remove Swing Motor and Swing Machinery Assembly2399
How to Install Swing Motor and Swing Machinery Assembly2400
Disassemble and Assemble Swing Machinery Assembly2402
How to Disassemble Swing Machinery Assembly2402
How to Assemble Swing Machinery Assembly2405
Remove and Install Swing Circle Assembly2413
How to Remove Swing Circle Assembly2413
How to Install Swing Circle Assembly2413
Undercarriage and Frame2415
Separate and Connect Track Assembly2415
How to Separate Track Assembly2415
How to Install Track Assembly2417
Remove and Install Sprocket2420
How to Remove Sprocket2420
How to Install Sprocket2420
Remove and Install Idler and Idler Cushion Assembly2422
How to Remove Idler and Idler Cushion Assembly2422
How to Install Idler and Idler Cushion Assembly2423
Disassemble and Assemble Idler Assembly2424
How to Disassemble Idler Assembly2424
How to Assemble Idler Assembly2425
Disassemble and Assemble Idler Cushion Assembly2429
How to Disassemble Idler Cushion Assembly2430
How to Assemble Idler Cushion Assembly2430
Disassemble and Assemble Track Roller Assembly2432
How to Disassemble Track Roller Assembly2433
How to Assemble Track Roller Assembly2434
Disassemble and Assemble Carrier Roller Assembly2436
How to Disassemble Carrier Roller Assembly2436
How to Assemble Carrier Roller Assembly2437
Remove and Install Revolving Frame Assembly2440
How to Remove Revolving Frame Assembly2440
How to Install Revolving Frame Assembly2442
Remove and Install Counterweight Assembly2445
How to Remove Counterweight Assembly2445
How to Install Counterweight Assembly2446
Hydraulic System2449
Remove and Install Center Swivel Joint Assembly2449
How to Remove Center Swivel Joint Assembly2449
How to Install Center Swivel Joint Assembly2450
Disassemble and Assemble Center Swivel Joint Assembly2453
How to Disassemble Center Swivel Joint Assembly2454
How to Assemble Center Swivel Joint Assembly2455
Remove and Install Hydraulic Tank Assembly2456
How to Remove Hydraulic Tank Assembly2456
How to Install Hydraulic Tank Assembly2460
Remove and Install Main Pump Assembly2464
How to Remove Main Pump Assembly2464
How to Install Main Pump Assembly2467
Remove and Install Control Valve Assembly2470
How to Remove Control Valve Assembly2470
How to Install Control Valve Assembly2477
Disassemble and Assemble Control Valve Assembly2484
How to Replace Pressure Compensation Valve Seal Ring2485
How to Assemble Control Valve Assembly2486
Remove and Install ATT Bypass Solenoid2491
How to Remove ATT Bypass Solenoid2491
How to Install ATT Bypass Solenoid2494
Disassemble and Assemble Work Equipment PPC Valve Assembly2496
How to Disassemble Work Equipment PPC Valve Assembly2496
How to Assemble Work Equipment PPC Valve Assembly2497
Disassemble and Assemble Travel PPC Valve Assembly2499
How to Disassemble Travel PPC Valve Assembly2499
How to Assemble Travel PPC Valve Assembly2500
Work Equipment2502
Remove and Install Bucket Assembly2502
How to Remove Bucket Assembly2502
How to Install Bucket Assembly2502
Remove and Install Arm Assembly2504
How to Remove Arm Assembly2504
How to Install Arm Assembly2505
Remove and Install Work Equipment Assembly2507
How to Remove Work Equipment Assembly2507
Install Work Equipment Assembly2510
Disassemble and Assemble Work Equipment Cylinder Assembly2513
How to Disassemble Work Equipment Cylinder Assembly2513
How to Assemble Work Equipment Cylinder Assembly2516
CAB Related Parts2523
Remove and Install Operator Cab Assembly2523
How to Remove Operator Cab Assembly2523
How to Install Operator Cab Assembly2531
Remove and Install Operator Cab Glass (Adhered Glass)2538
How to Remove Operator Cab Glass (Adhered Glass)2540
How to Install Operator Cab Glass (Adhered Glass)2540
Remove and Install Front Window Assembly2550
How to Remove Front Window Assembly2550
How to Install Front Window Assembly2553
Remove and Install Floor Frame Assembly2559
How to Remove Floor Frame Assembly2560
How to Install Floor Frame Assembly2566
Remove and Install Air Conditioner Unit Assembly2574
How to Remove Air Conditioner Unit Assembly2574
How to Install Air Conditioner Unit Assembly2579
Remove and Install Operator Seat2585
How to Remove Operator Seat2585
How to Install Operator Seat2587
How to Remove and Install Seat Belt2590
How to Remove Seat Belt2590
How to Install Seatbelt2591
Remove and Install Front Wiper Assembly2592
How to Remove Front Wiper Assembly2592
How to Install Front Wiper Assembly2597
Electrical System2606
Remove and Install Engine Controller Assembly2606
How to Remove Engine Controller Assembly2606
How to Install Engine Controller Assembly2608
Remove and Install Pump Controller Assembly2612
How to Remove Pump Controller Assembly2612
How to Install Pump Controller Assembly2615
Remove and Install KomVision Controller Assembly2619
How to Remove KomVision Controller Assembly2619
How to Install KomVision Controller Assembly2620
Remove and Install Machine Monitor Assembly2621
How to Remove Machine Monitor Assembly2621
How to Install Machine Monitor Assembly2624
Remove and Install Pump Swash Plate Sensor2628
How to Remove Pump Swash Plate Sensor2628
How to Install Pump Swash Plate Sensor2628
Remove and Install Mass Air Flow and Temperature Sensor2630
How to Remove Mass Air Flow and Temperature Sensor2630
How to Install Mass Air Flow and Temperature Sensor2631
Remove and Install KCCV Crankcase Pressure Sensor2632
How to Remove KCCV Crankcase Pressure Sensor2632
How to Install KCCV Crankcase Pressure Sensor2633
Remove and Install SCR Temperature Sensor2634
How to Remove SCR Temperature Sensor2634
How to Install SCR Temperature Sensor2635
Remove and Install Rearview Camera2637
How to Remove Rearview Camera2637
How to Install Rearview Camera2638
Remove and Install KomVision Camera2640
How to Remove KomVision Camera2640
How to Install KomVision Camera2641
Remove and Install Gateway Function Controller Assembly2643
How to Remove Gateway Function Controller Assembly2643
How to Install Gateway Function Controller Assembly2648
Remove and Install Communication Terminal Wiring Harness2653
How to Remove Communication Terminal Wiring Harness2653
How to Install Communication Terminal Wiring Harness2661
Remove and Install Communication Terminal2670
How to Remove Communication Terminal2670
How to Install Communication Terminal2672
60 Maintenance Standard2675
Table of Contents2676
Engine and Cooling System2677
Maintenance Standard for Engine Mount2677
Maintenance Standard for Cooling System2679
Power Train2680
Maintenance Standard for Swing Circle2680
Maintenance Standard for Swing Machinery2681
Maintenance Standard for Final Drive2683
Maintenance Standard for Sprocket2685
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2686
Undercarriage and Frame2687
Maintenance Standard for Track Frame and Idler Cushion2687
Maintenance Standard for Idler2689
Maintenance Standard for Track Roller2691
Maintenance Standard for Carrier Roller2693
Maintenance Standard for Track Shoes2694
Maintenance Standard for Triple Shoes2697
Hydraulic System2698
Maintenance Standard for Hydraulic Tank2698
Maintenance Standard for Main Pump2699
Maintenance Standard for Swing Motor2701
Maintenance Standard for Travel Motor2704
Maintenance Standard for Control Valve2707
Maintenance Standard for Work Equipment and Swing PPC Valve2717
Maintenance Standard for Travel PPC Valve2720
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2723
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2724
Maintenance Standard for 2nd-Line Attachment PPC Valve2726
Maintenance Standard for Solenoid Valve2728
Maintenance Standard of Hydraulic Drift Prevention Valve2729
Maintenance Standard for Attachment Circuit Selector Valve2731
Maintenance Standard for Center Swivel Joint2732
Work Equipment2733
Maintenance Standard for Work Equipment Linkage2733
Dimension of Arm2738
Dimensions of Bucket2740
Maintenance Standard for Boom Cylinder2742
Maintenance Standard for Arm Cylinder2743
Maintenance Standard for Bucket Cylinder2744
80 Appendix2745
Table of Contents2746
Precautions Before Work2748
Air Conditioner System2749
Precautions for Refrigerant2749
Air Conditioner Component2750
Specifications of Air Conditioner2752
Structure and Function of Refrigeration Cycle2753
Outline of Refrigeration Cycle2754
Component Parts of Air Conditioner System2756
Air Conditioner Unit2756
Configuration Diagram of Air Conditioner Unit2756
Function of Air Conditioner Unit2758
Component Parts of Air Conditioner Unit2760
Function of Evaporator as Air Conditioner Unit Component2761
Function of Heater Core as Air Conditioner Unit Component2761
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2761
Function of Servo Motor as Air Conditioner Unit Component2761
Structure of Expansion Valve as Air Conditioner Unit Component2762
Function of Expansion Valve as Air Conditioner Unit Component2762
Operate Expansion Valve as Air Conditioner Unit Component2762
Function of Dual Pressure Switch2763
Air Conditioner Controller2764
Structure of Air Conditioner Controller2764
Compressor2765
Structure of Compressor2765
Specifications of Compressor2765
Function of Compressor2765
Condenser2766
Structure of Condenser2766
Specifications of Condenser2766
Function of Condenser2766
Receiver Drier2767
Structure of Receiver Dryer2767
Specifications of Receiver Dryer2767
Function of Receiver Dryer2767
Air Conditioner Related Sensors2768
Structure of Sunlight Sensor2768
Function of Sunlight Sensor2768
Structure of Outside Temperature Sensor2768
Function of Outside Air Temperature Sensor2768
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2770
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2772
System Diagram of Air Conditioner2774
Input and Output Signals of Air Conditioner Controller2775
Function of Air Conditioner Controller2776
Locations of Air Conditioner Parts and Layout of Connectors2777
Examine Air Leakage (Duct)2781
How to Examine Air Leakage (Duct)2781
Examine Air Conditioner with Self-Diagnosis Function2783
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2784
Examine Vent (Mode) Changeover2785
How to Examine Vent (Mode) Changeover2785
Examine Fresh/Recirc Air Changeover2787
How to Examine Fresh/Recirc Air Changeover2787
Examine Sunlight Sensor2788
How to Examine Sunlight Sensor2788
Examine Refrigerant (Dual) Pressure Switch2789
How to Examine Refrigerant (Dual) Pressure Switch2789
Examine Relay2790
How to Examine Relay2790
Air Conditioner Troubleshooting Chart 12791
Air Conditioner Troubleshooting Chart 22792
Information Shown in Troubleshooting Table2795
Failure Code [879AKA]2796
Failure Code [879AKB]2797
Failure Code [879BKA]2798
Failure Code [879BKB]2800
Failure Code [879CKA]2802
Failure Code [879CKB]2803
Failure Code [879DKZ]2804
Failure Code [879EMC]2806
Failure Code [879FMC]2807
Failure Code [879GKX]2808
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2810
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2812
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2815
A-4 Troubleshooting for FRESH/RECIRC Air Changeover2817
Troubleshooting by Gauge Pressure2819
Connect Service Tool2822
How to Connect Service Tool2822
Precautions for Disconnection and Connection of Air Conditioner Piping2824
Handle Compressor Oil2826
90 Circuit Diagrams2829
Table of Contents2830
Hydraulic Circuit Diagram2831
Symbols Used in Hydraulic Circuit Diagram2831
Hydraulic Circuit Diagram (1/3)2835
Hydraulic Circuit Diagram (2/3)2837
Hydraulic Circuit Diagram (3/3)2839
Electrical Circuit Diagram2841
Symbols Used in Electric Circuit Diagram2841
Electrical Diagram (1/12)2845
Electrical Diagram (2/12)2847
Electrical Diagram (3/12)2849
Electrical Diagram (4/12)2851
Electrical Diagram (5/12)2853
Electrical Diagram (6/12)2855
Electrical Diagram (7/12)2857
Electrical Diagram (8/12)2859
Electrical Diagram (9/12)2861
Electrical Diagram (10/12)2863
Electrical Diagram (11/12)2865
Electrical Diagram (12/12)2867
Index2869

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24