Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06494-18 PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06494-18 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06494-18 – PDF DOWNLOAD

Language : English
Pages :2938
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06494-18 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06494-18 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

Cover 2
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 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
01 Specifications 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: PC490LC-11 91
Working Range Drawings 93
Working Range: PC490LC-11 93
Specifications 94
Specifications: PC490LC-11 94
Weight Table 97
Weight Table: PC490LC-11 97
Table of Fuel, Coolant, and Lubricants 99
10 Structure and Function 101
Table of Contents 102
Urea SCR System 106
Layout Drawing of Urea SCR System 106
Urea SCR System Diagram 110
Function of Urea SCR System 111
Function of DEF System 111
Inducement Strategy 114
Component Parts of Urea SCR System 128
DEF Mixing Tube 128
SCR Assembly 129
DEF Tank 131
DEF Pump 133
DEF Injector 134
DEF Hose 135
DEF Tank Heating Valve 136
Boot-up System 137
Layout Drawing of Boot-up System 137
System Operating Lamp System 139
System Diagram of System Operating Lamp System 139
Function of Operation Lamp System 139
Battery Disconnect Switch 141
Function of Battery Disconnect Switch 141
Engine System 142
Layout Drawing of Engine System 142
Specifications of Engine System 143
Function of Engine System 144
Engine Control System 145
System Diagram of Engine Control 145
Function of Engine Control System 146
Auto-Deceleration System 148
System Diagram of Auto-Deceleration System 148
Function of Auto-Deceleration System 148
Operation of Auto-Deceleration System 149
Engine Automatic Warm-up System 150
System Diagram of Engine Automatic Warm-up System 150
Function of Engine Automatic Warm-up System 151
Overheat Prevention System 152
Overheat Prevention System Diagram 152
Function of Overheat Prevention System 153
Turbocharger Protection System 155
System Diagram of Turbocharger Protection System 155
Function of Turbocharger Protection System 156
Automatic Idle Stop System 157
System Diagram of Automatic Idle Stop System 157
Function of Automatic Idle Stop System 157
Component Parts of Engine System 160
VGT 160
EGR System 163
EGR Valve 165
EGR Cooler 167
KCCV System 168
KCCV Ventilator 169
KDPF 171
Cooling System 176
Layout Drawing of Cooling System 176
Specifications of Cooling System 177
Fan Speed Control System of Hydraulic Fan 179
Fan Speed Control System Diagram of Hydraulic Fan 179
Function of Fan Speed Control System of Hydraulic Fan 180
Engine Output Control System of Hydraulic Fan 181
Engine Output Control System Diagram of Hydraulic Fan 181
Function of Engine Output Control System of Hydraulic Fan 182
Fan Reverse Rotation System of Hydraulic Fan 184
Fan Reverse Rotation System Diagram of Hydraulic Fan 184
Function of Fan Reverse Rotation System of Hydraulic Fan 184
Component Parts of Cooling System 185
Cooling Fan Pump 185
Cooling Fan Motor 192
Control System 199
Layout Drawing of Control System 199
Machine Monitor System 202
System Diagram of Machine Monitor System 202
KomVision System 203
Layout Drawing of KomVision System 203
System Diagram of KomVision System 205
Function of KomVision System 205
KOMTRAX System 207
System Diagram of KOMTRAX System 207
Function of KOMTRAX System 207
Component Parts of Control System 208
Machine Monitor 208
KomVision Controller 221
KomVision Camera 225
KOMTRAX Terminal 225
Pump Controller 228
Resistor for PC-EPC Valve 232
CAN Terminating Resistor 232
Engine Controller 234
Fuel Control Dial 240
Fuel Feed Pump 242
Fuel Feed Pump Switch 243
Hydraulic System 244
Layout Drawing of Hydraulic System 244
CLSS 246
Structure of CLSS 246
Operation of Unload Valve and LS Pressure 248
Pump Swash Plate Angle (Oil Flow) Control 249
Pressure Compensation Control 265
Engine and Pump Combined Control System 269
Engine and Pump Combined Control System Diagram 269
Function of Engine and Pump Combined Control System 271
Pump and Valve Control System 276
Pump and Valve Control System Diagram 276
Function of Pump and Valve Control System 277
Component Parts of Hydraulic System 279
Hydraulic Tank 279
Main Pump 281
Control Valve 307
Work Equipment System 370
Layout Drawing of Work Equipment System 370
Structure of Valve Control 375
One-Touch Power Maximizing System 376
System Diagram of One-Touch Power Maximizing System 376
Function of One-Touch Power Maximizing System 377
Machine Push-up System 378
Machine Push-up System Diagram 378
Function of Machine Push-up System 379
PPC Lock System 380
System Diagram of PPC Lock 380
Function of PPC Lock System 380
Work Equipment and Travel Automatic Lock System 381
System Diagram of Lock Lever Automatic Lock System 381
Function of Work Equipment and Travel Automatic Lock System 381
Operation of Lock Lever Automatic Lock System 382
Attachment Oil Flow Adjuster System 383
Attachment Oil Flow Adjuster System Diagram 383
Function of Attachment Oil Flow Adjuster System 384
Tool Control System 385
Tool Control System Diagram 385
Function of Tool Control System 386
Component Parts of Work Equipment System 387
Work Equipment and Swing PPC Valve 387
1st-Line Attachment PPC Valve (with EPC Valve) 393
Solenoid Valve 398
Boom Anti-drop Valve 400
Arm Anti-Drop Valve 404
Attachment Circuit Selector Valve (For High Pressure) 408
Attachment Circuit Selector Valve (For Low Pressure) 410
1st-Line Attachment Variable Relief Valve 413
Attachment Bypass Solenoid Valve 416
Pilot Circuit Accumulator 417
Swing System 418
Layout Drawing of Swing System 418
Swing Control System Diagram 424
Function of Swing Control System 424
Component Parts of Swing System 428
Swing Motor 428
Swing Machinery 439
Swing Circle 441
Travel System 443
Layout Drawing of Travel System 443
System Diagram of Travel Control System 447
Function of Travel Control System 448
Component Parts of Travel System 449
Travel Motor 449
Final Drive 462
Travel PPC Valve 463
Center Swivel Joint 468
Undercarriage and Frame 470
Layout Drawing of Undercarriage 470
Specifications of Undercarriage 470
Work Equipment 471
Structure of Work Equipment 471
Function of Work Equipment 472
Work Equipment Clearance Adjustment Shim 473
Function of Work Equipment Clearance Adjustment Shim 473
Bucket Clearance Adjustment Shim 474
Function of Bucket Clearance Adjustment Shim 474
CAB Related Parts 475
ROPS CAB 475
Structure of ROPS CAB 475
Function of ROPS CAB 475
CAB Mount 476
Structure of CAB Mount 476
Function of CAB Mount 476
CAB Tipping Stopper 477
Structure of CAB Tipping Stopper 477
Function of CAB Tipping Stopper 477
20 Standard Value Table 479
Table of Contents 480
Standard Value Table for Engine 481
Standard Value Table for Engine: PC490LC-11 481
Standard Value Table for Machine 484
Standard Value Table for Machine: PC490LC-11 484
Machine Posture and Procedures to Measure Performance 500
Standard Value Table for Electricity 504
Standard Value Table for Electricity 504
30 Testing and Adjusting 515
Table of Contents 516
Precautions Before Work 519
Related Information on Testing and Adjusting 520
Tools for Testing and Adjusting 520
Sketch of Tools for Testing and Adjusting 528
Engine and Cooling System 530
Examine Engine Speed 530
How to Examine Engine Speed 530
Examine Boost Pressure 533
How to Examine Boost Pressure on Machine Monitor 533
How to Examine Boost Pressure by Testing Tool 534
Examine Exhaust Gas Color 535
How to Examine Exhaust Gas Color with the Handy Smoke Checker 535
How to Examine Exhaust Gas Color with Smoke Meter 536
Examine Mass Air Flow and Temperature Sensor 537
How to Examine Mass Air Flow and Temperature Sensor 537
Examine and Adjust Valve Clearance 539
How to Examine Valve Clearance 539
How to Adjust Valve Clearance 542
Examine Compression Pressure 543
How to Examine Compression Pressure 543
Examine Blowby Pressure 546
How to Examine Blowby Pressure 546
Examine Engine Oil Pressure 548
How to Examine Engine Oil Pressure on Machine Monitor 548
How to Examine Engine Oil Pressure by Testing Tool 548
Examine EGR Valve and VGT Oil Pressure 550
How to Examine EGR Valve and VGT Oil Pressure 550
Examine Fuel Pressure 552
How to Examine Fuel Pressure 552
Examine Fuel Return Rate and Leakage 554
How to Examine Fuel Return Rate and Leakage 554
Bleed Air from Fuel System 557
How to Bleed Air from Fuel System 557
Examine Fuel Circuit for Leakage 559
How to Examine Fuel System for Leakage 559
Handle Cylinder Cut-out Mode Operation 561
Handle No-Injection Cranking Operation 562
Examine and Adjust Air Conditioner Compressor Belt Tension 563
How to Examine Air Conditioner Compressor Belt Tension 563
How to Adjust Air Conditioner Compressor Belt Tension 563
Clean Fuel Doser 565
How to Clean Fuel Doser 565
Write Injector Compensation Value to Engine Controller 567
How to Write Injector Compensation Value 567
Write Correction for Ash in Soot Accumulation to Engine Controller 573
How to Write Correction for Ash in Soot Accumulation to Engine Controller 573
Examine SCR Related Functions 574
Examine DEF Pump Raised Pressure 577
Examine Injection Volume from DEF Injector 580
Examine DEF Line Heater Relay 1 584
Examine DEF Line Heater Relay 2 586
Examine DEF Pump Heater Relay 589
Examine DEF Tank Heater Valve 592
Examine SCR Denitration Efficiency 595
Clean DEF Tank 599
How to Clean DEF Tank 599
Clean DEF Pump 603
How to Clean DEF Pump 603
Power Train 610
Examine Swing Circle Bearing Clearance 610
How to Examine Swing Circle Bearing Clearance 610
Undercarriage and Frame 611
Examine and Adjust Track Tension 611
How to Examine Track Tension 611
How to Adjust Track Tension 611
Hydraulic System 613
Release Remained Pressure in Hydraulic Circuit 613
How to Release Remained Pressure in Hydraulic System 613
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 616
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 617
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 623
Examine Oil Pressure of Control Circuit 627
How to Examine Oil Pressure in Control Circuit 627
Examine and adjust oil pressure in pump PC control circuit 629
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 629
Examine PC-EPC Valve Outlet Pressure 630
How to Adjust Oil Pressure in Pump PC Control Circuit 631
Examine and Adjust Oil Pressure in Pump LS Control Circuit 633
How to Examine LS Differential Pressure with Machine Monitor 633
How to Examine LS Differential Pressure by Testing Tool 634
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 635
How to Examine LS-EPC Valve Outlet Pressure 636
How to Adjust LS Valve 637
Examine Outlet Pressure of Solenoid Valve 638
How to Examine Outlet Pressure of Solenoid Valve 638
Operating Condition of Solenoid Valve 639
Examine PPC Valve Outlet Pressure 641
How to Examine Outlet Pressure in PPC Valve 641
Adjust Play of Work Equipment and Swing PPC Valves 643
How to Adjust Play of Work Equipment and Swing PPC Valves 643
Examine Pump Swash Plate Sensor 644
How to Examine pump swash plate sensor 644
Examine Cooling Fan Speed 645
How to Examine Cooling Fan Speed 645
Examine Oil Pressure in Fan Pump Circuit 646
How to Examine Oil Pressure in Fan Pump Circuit 646
Examine Fan Pump EPC Electric Current 648
How to Examine Fan Pump EPC Electric Current 648
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 649
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 649
Examine Parts Which Cause Hydraulic Drift of Work Equipment 651
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 651
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 651
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 652
Examine Oil Leakage 653
Examine Oil Leakage from Boom Cylinder 653
Examine Oil Leakage of Arm Cylinder 653
Examine Oil Leakage of Bucket Cylinder 654
How to Examine Oil Leakage of Swing Motor 654
How to Examine Oil Leakage of Travel Motor 655
Bleed Air from Hydraulic System 656
How to Bleed Air from Hydraulic System 658
CAB Related Parts 661
Examine CAB Tipping Stopper 661
How to Examine Cab Tipping Stopper 661
How to Adjust Mirrors 662
Procedure to Adjust Machine Left Front Mirror (A) 662
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 663
Procedure to Adjust Machine Right Front Mirror (B) 664
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 665
Procedure to Adjust Machine Right Side Mirror (C) 666
Electrical System 668
Set and Operate Machine Monitor 668
Operator Mode 671
Function to Show Technician Identification Status Screen 672
Function to Show Operator Identification Input Screen 672
Examine Function by LCD (Liquid Crystal Display) 673
Examine Function of Service Meter 673
Usage Limitation and Maintenance Password Change Function 673
Service Mode 676
How to Operate Service Mode 676
How to See Pre-defined Monitoring Information 678
How to Examine Self-Define Monitor Information 685
Abnormality Record Menu 696
How to See Maintenance Record 701
Maintenance Mode Setting 702
How to Set Phone Number Entry 706
Default Menu 707
Diagnostic Tests Menu 719
Adjustment Menu 729
No-Injection Cranking Operation 747
KOMTRAX Settings Menu 748
How to Show Service Message 750
How to Start Up KOMTRAX Terminal 752
Adjust Rearview Camera Angle 757
How to Adjust Rearview Camera Angle 757
Adjust KomVision Camera Angle 760
How to Adjust KomVision Camera Angle 761
Adjust KomVision Related Function 765
Setting of KomVision (Main Setting) 766
Setting of KomVision (Camera Setting) 768
Setting of KomVision (Camera Calibration) 771
KomVision screen – Check 12 m visibility 784
Set Region of Bluetooth(R) Compatible Radio 787
How to Set Region of Bluetooth(R) Compatible Radio 787
Handle Voltage Circuit of Engine Controller 789
Handle Battery Disconnect Switch 790
Examine Diodes 791
How to Examine Diodes by Digital Tester 791
How to Examine Diodes by Analog Tester 791
Pm Clinic 792
Pm Clinic Service 792
Pm Clinic Check Sheet 793
40 Troubleshooting 807
Table of Contents 808
Precautions Before Work 819
Related Information to Troubleshooting 820
General Troubleshooting Points 820
Troubleshooting Points for Urea SCR System 821
Sequence of Events in Troubleshooting 835
Checks Before Troubleshooting 837
Inspection Procedure Before Troubleshooting 839
Walk-Around Check 839
Test in Accordance with Testing Procedure 841
Examine Fuel Level and Type 841
Examine for Impure Ingredient in Fuel 842
Examine Fuel Prefilter 842
Examine Water Separator, Drain Water and Sediment 842
Replace Fuel Prefilter Cartridge 843
Examine Fuel Main Filter 844
Examine Engine Oil Level (Oil Quantity in Oil Pan) 845
Examine Coolant Level (Reservoir Tank) 847
Examine Air Cleaner Clogging 847
Clean Outer Element 848
Replace Element 850
Examine Hydraulic Oil Level 851
Examine Hydraulic Oil Strainer 851
Examine Hydraulic Oil Filter 852
Examine Oil Level in Swing Machinery Case 853
Examine Oil Level in Damper Case 854
Examine Oil Level in Final Drive Case 854
Bleed Air from Fuel System 855
Bleed Air from Hydraulic System 855
How to Examine Electric Equipment 855
Preparation for Troubleshooting of Electrical System 861
Procedure for Troubleshooting 871
Symptom and Troubleshooting Numbers 874
Information Shown in Troubleshooting Table 878
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 [879AKA] 967
Failure Code [879AKB] 968
Failure Code [879BKA] 969
Failure Code [879BKB] 971
Failure Code [879CKA] 973
Failure Code [879CKB] 974
Failure Code [879DKZ] 975
Failure Code [879EMC] 977
Failure Code [879FMC] 978
Failure Code [879GKX] 979
Failure Code [989L00] 981
Failure Code [989M00] 982
Failure Code [989N00] 983
Failure Code [A1U0N3] 984
Failure Code [A1U0N4] 986
Failure Code [A900FR] 988
Failure Code [A900N6] 989
Failure Code [A900NY] 990
Failure Code [AA10NX] 991
Failure Code [AB00KE] 993
Failure Code [AQ10N3] 996
Failure Code [AS00N3] 998
Failure Code [AS00R2]1000
Failure Code [AS00R3]1001
Failure Code [AS00R4]1002
Failure Code [AS00R5]1003
Failure Code [AS00R6]1004
Failure Code [AS00ZK]1005
Failure Code [AS10KM]1006
Failure Code [AS10NR]1007
Failure Code [AS10NT]1008
Failure Code [B@BAZG]1009
Failure Code [B@BAZK]1010
Failure Code [B@BCNS]1012
Failure Code [B@BCQA]1013
Failure Code [B@BCZK]1015
Failure Code [B@HANS]1017
Failure Code [CA115]1018
Failure Code [CA122]1019
Failure Code [CA123]1021
Failure Code [CA131]1023
Failure Code [CA132]1025
Failure Code [CA135]1027
Failure Code [CA141]1029
Failure Code [CA144]1031
Failure Code [CA145]1033
Failure Code [CA153]1035
Failure Code [CA154]1038
Failure Code [CA187]1041
Failure Code [CA221]1043
Failure Code [CA222]1045
Failure Code [CA227]1047
Failure Code [CA234]1048
Failure Code [CA238]1049
Failure Code [CA239]1051
Failure Code [CA249]1053
Failure Code [CA256]1055
Failure Code [CA271]1057
Failure Code [CA272]1059
Failure Code [CA273]1060
Failure Code [CA274]1062
Failure Code [CA322]1063
Failure Code [CA323]1065
Failure Code [CA324]1067
Failure Code [CA325]1069
Failure Code [CA331]1071
Failure Code [CA332]1073
Failure Code [CA343]1075
Failure Code [CA351]1076
Failure Code [CA352]1077
Failure Code [CA356]1080
Failure Code [CA357]1082
Failure Code [CA386]1084
Failure Code [CA441]1085
Failure Code [CA442]1087
Failure Code [CA449]1088
Failure Code [CA451]1089
Failure Code [CA452]1091
Failure Code [CA515]1093
Failure Code [CA516]1095
Failure Code [CA553]1097
Failure Code [CA555]1098
Failure Code [CA556]1099
Failure Code [CA559]1100
Failure Code [CA595]1105
Failure Code [CA687]1106
Failure Code [CA689]1108
Failure Code [CA691]1110
Failure Code [CA692]1112
Failure Code [CA697]1114
Failure Code [CA698]1115
Failure Code [CA731]1116
Failure Code [CA778]1117
Failure Code [CA1117]1120
Failure Code [CA1664]1121
Failure Code [CA1669]1124
Failure Code [CA1673]1125
Failure Code [CA1677]1126
Failure Code [CA1678]1127
Failure Code [CA1682]1128
Failure Code [CA1683]1130
Failure Code [CA1684]1132
Failure Code [CA1686]1134
Failure Code [CA1691]1135
Failure Code [CA1694]1138
Failure Code [CA1695]1140
Failure Code [CA1696]1141
Failure Code [CA1712]1143
Failure Code [CA1713]1146
Failure Code [CA1714]1148
Failure Code [CA1715]1149
Failure Code [CA1776]1150
Failure Code [CA1777]1153
Failure Code [CA1843]1156
Failure Code [CA1844]1158
Failure Code [CA1879]1161
Failure Code [CA1881]1164
Failure Code [CA1883]1166
Failure Code [CA1885]1169
Failure Code [CA1887]1171
Failure Code [CA1921]1173
Failure Code [CA1922]1176
Failure Code [CA1923]1181
Failure Code [CA1924]1183
Failure Code [CA1925]1185
Failure Code [CA1927]1187
Failure Code [CA1928]1189
Failure Code [CA1942]1191
Failure Code [CA1963]1192
Failure Code [CA1977]1195
Failure Code [CA1993]1198
Failure Code [CA2185]1201
Failure Code [CA2186]1203
Failure Code [CA2249]1205
Failure Code [CA2265]1206
Failure Code [CA2266]1208
Failure Code [CA2271]1210
Failure Code [CA2272]1212
Failure Code [CA2349]1214
Failure Code [CA2353]1216
Failure Code [CA2357]1218
Failure Code [CA2381]1219
Failure Code [CA2382]1221
Failure Code [CA2383]1223
Failure Code [CA2386]1225
Failure Code [CA2387]1227
Troubleshooting Flowchart1231
Failure Code [CA2555]1232
Failure Code [CA2556]1235
Failure Code [CA2637]1237
Failure Code [CA2639]1239
Failure Code [CA2732]1242
Failure Code [CA2733]1244
Failure Code [CA2741]1246
Failure Code [CA2765]1247
Failure Code [CA2771]1248
Failure Code [CA2777]1254
Failure Code [CA2878]1257
Failure Code [CA2881]1260
Failure Code [CA2976]1263
Failure Code [CA3133]1265
Failure Code [CA3134]1267
Failure Code [CA3135]1269
Failure Code [CA3142]1272
Failure Code [CA3143]1273
Failure Code [CA3144]1274
Failure Code [CA3146]1276
Failure Code [CA3147]1277
Failure Code [CA3148]1278
Failure Code [CA3151]1280
Failure Code [CA3165]1286
Failure Code [CA3167]1288
Failure Code [CA3229]1291
Failure Code [CA3231]1293
Failure Code [CA3232]1295
Failure Code [CA3235]1299
Failure Code [CA3239]1301
Failure Code [CA3241]1304
Failure Code [CA3242]1307
Failure Code [CA3251]1310
Failure Code [CA3253]1312
Failure Code [CA3254]1315
Failure Code [CA3255]1318
Failure Code [CA3256]1322
Failure Code [CA3311]1324
Failure Code [CA3312]1326
Failure Code [CA3313]1329
Failure Code [CA3314]1330
Failure Code [CA3315]1331
Failure Code [CA3316]1334
Failure Code [CA3317]1335
Failure Code [CA3318]1336
Failure Code [CA3319]1338
Failure Code [CA3321]1339
Failure Code [CA3322]1341
Failure Code [CA3419]1344
Failure Code [CA3421]1346
Failure Code [CA3497]1348
Failure Code [CA3498]1349
Failure Code [CA3543]1350
Failure Code [CA3545]1357
Failure Code [CA3547]1359
Failure Code [CA3558]1360
Failure Code [CA3559]1362
Failure Code [CA3562]1364
Failure Code [CA3563]1366
Failure Code [CA3567]1369
Failure Code [CA3568]1372
Failure Code [CA3571]1376
Failure Code [CA3572]1378
Failure Code [CA3574]1380
Failure Code [CA3575]1382
Failure Code [CA3577]1384
Failure Code [CA3578]1386
Failure Code [CA3582]1388
Failure Code [CA3583]1394
Failure Code [CA3596]1396
Failure Code [CA3649]1398
Failure Code [CA3681]1400
Failure Code [CA3682]1405
Failure Code [CA3713]1411
Failure Code [CA3717]1414
Failure Code [CA3718]1415
Failure Code [CA3725]1416
Failure Code [CA3748]1419
Failure Code [CA3751]1421
Failure Code [CA3755]1423
Failure Code [CA3866]1425
Failure Code [CA3867]1429
Failure Code [CA3868]1432
Failure Code [CA3899]1436
Failure Code [CA3911]1438
Failure Code [CA3912]1442
Failure Code [CA3932]1444
Failure Code [CA3933]1446
Failure Code [CA3934]1448
Failure Code [CA3935]1451
Failure Code [CA3936]1453
Failure Code [CA4151]1455
Failure Code [CA4152]1459
Failure Code [CA4155]1463
Failure Code [CA4156]1465
Failure Code [CA4157]1468
Failure Code [CA4158]1470
Failure Code [CA4159]1471
Failure Code [CA4161]1472
Failure Code [CA4162]1475
Failure Code [CA4163]1478
Failure Code [CA4164]1480
Failure Code [CA4165]1482
Failure Code [CA4166]1484
Failure Code [CA4168]1486
Failure Code [CA4169]1489
Failure Code [CA4171]1491
Failure Code [CA4249]1494
Failure Code [CA4251]1496
Failure Code [CA4259]1498
Failure Code [CA4261]1500
Failure Code [CA4277]1503
Failure Code [CA4281]1507
Failure Code [CA4459]1510
Failure Code [CA4461]1512
Failure Code [CA4658]1515
Failure Code [CA4731]1519
Failure Code [CA4732]1520
Failure Code [CA4739]1521
Failure Code [CA4768]1522
Failure Code [CA4769]1524
Failure Code [CA4842]1527
Failure Code [CA4952]1531
Failure Code [CA5115]1533
Failure Code [CA5179]1536
Failure Code [CA5181]1538
Failure Code [CA5383]1540
Failure Code [D110KB]1542
Failure Code [D19JKZ]1544
Failure Code [D811MC]1547
Failure Code [D862KA]1548
Failure Code [D8ALKA]1549
Failure Code [D8ALKB]1551
Failure Code [D8AQKR]1553
Failure Code [DA20MC]1555
Failure Code [DA22KK]1556
Failure Code [DA25KP]1559
Failure Code [DA26KP]1562
Failure Code [DA29KQ]1564
Failure Code [DA2LKA]1566
Failure Code [DA2LKB]1568
Failure Code [DA2QKR]1570
Failure Code [DA2RKR]1573
Failure Code [DAF0KM]1574
Failure Code [DAF0MB]1575
Failure Code [DAF0MC]1576
Failure Code [DAF8KB]1577
Failure Code [DAF9KQ]1579
Failure Code [DAFGMC]1580
Failure Code [DAFLKA]1581
Failure Code [DAFLKB]1583
Failure Code [DAFQKR]1585
Failure Code [DAZ9KQ]1586
Failure Code [DAZQKR]1587
Failure Code [DB2QKR]1592
Failure Code [DB2RKR]1597
Failure Code [DBP0KM]1601
Failure Code [DBP0KT]1602
Failure Code [DBP5KB]1603
Failure Code [DBP5KY]1606
Failure Code [DBPQKR]1609
Failure Code [DDNRKA]1614
Failure Code [DDNRKY]1616
Failure Code [DDNS00]1618
Failure Code [DFB1KZ]1620
Failure Code [DFB2KZ]1622
Failure Code [DFB3L8]1624
Failure Code [DFB4L8]1626
Failure Code [DFB5KZ]1628
Failure Code [DFB6KZ]1630
Failure Code [DGH2KA]1632
Failure Code [DGH2KB]1634
Failure Code [DHA4KA]1636
Failure Code [DHAAMA]1638
Failure Code [DHACMA]1640
Failure Code [DHPAMA]1642
Failure Code [DHPBMA]1645
Failure Code [DHS3MA]1648
Failure Code [DHS4MA]1651
Failure Code [DHS8MA]1654
Failure Code [DHS9MA]1657
Failure Code [DHSAMA]1660
Failure Code [DHSBMA]1663
Failure Code [DHSCMA]1666
Failure Code [DHSDMA]1669
Failure Code [DHSFMA]1672
Failure Code [DHSGMA]1675
Failure Code [DHSHMA]1678
Failure Code [DHSJMA]1681
Failure Code [DHSVMA]1684
Failure Code [DHZAMA]1687
Failure Code [DHZCL8]1691
Failure Code [DKR0MA]1692
Failure Code [DKR1MA]1695
Failure Code [DKULKA]1698
Failure Code [DKULKB]1700
Failure Code [DKULKY]1702
Failure Code [DLM3KA]1704
Failure Code [DLM3KB]1706
Failure Code [DLM3MB]1708
Failure Code [DR10KA]1709
Failure Code [DR12KA]1712
Failure Code [DR20KA]1714
Failure Code [DR21KX]1716
Failure Code [DR30KA]1718
Failure Code [DR31KX]1720
Failure Code [DR40KA]1722
Failure Code [DUMBKA]1724
Failure Code [DUMBKB]1726
Failure Code [DV20KB]1728
Failure Code [DW43KA]1730
Failure Code [DW43KB]1732
Failure Code [DW43KY]1734
Failure Code [DW45KA]1736
Failure Code [DW45KB]1739
Failure Code [DW45KY]1742
Failure Code [DW4CKY]1744
Failure Code [DW7BKA]1745
Failure Code [DW7BKB]1747
Failure Code [DW7BKY]1749
Failure Code [DW91KA]1750
Failure Code [DW91KB]1752
Failure Code [DW91KY]1754
Failure Code [DWA2KA]1756
Failure Code [DWA2KB]1758
Failure Code [DWA2KY]1760
Failure Code [DWK0KA]1762
Failure Code [DWK0KB]1764
Failure Code [DWK0KY]1766
Failure Code [DWK2KA]1768
Failure Code [DWK2KB]1770
Failure Code [DWK2KY]1772
Failure Code [DWK8KA]1774
Failure Code [DWPUKA]1776
Failure Code [DWPUKB]1778
Failure Code [DWPUKY]1780
Failure Code [DWK8KB]1782
Failure Code [DWK8KY]1784
Failure Code [DX16KA]1786
Failure Code [DX16KB]1788
Failure Code [DXA8KA]1790
Failure Code [DXA8KB]1792
Failure Code [DXA9KA]1794
Failure Code [DXA9KB]1796
Failure Code [DXE0KA]1798
Failure Code [DXE0KB]1800
Failure Code [DXE4KA]1802
Failure Code [DXE4KB]1804
Failure Code [DXE4KY]1806
Failure Code [DXE5KA]1808
Failure Code [DXE5KB]1810
Failure Code [DXE6KA]1812
Failure Code [DXE6KB]1814
Failure Code [DXE7KA]1816
Failure Code [DXE7KB]1818
Failure Code [DXE7KY]1820
Failure Code [DXE8KA]1822
Failure Code [DXE8KB]1824
Failure Code [DXE8KY]1826
Failure Code [DXE9KA]1828
Failure Code [DXE9KB]1830
Failure Code [DXE9KY]1832
Failure Code [DXEAKA]1834
Failure Code [DXEAKB]1836
Failure Code [DXEAKY]1838
Failure Code [DXEKKA]1840
Failure Code [DXEKKB]1842
Failure Code [DXEKKY]1844
Failure Code [DXELKA]1846
Failure Code [DXELKB]1848
Failure Code [DXELKY]1850
Failure Code [DY20KA]1852
Failure Code [DY20MA]1854
Failure Code [DY2CKB]1856
Failure Code [DY2DKB]1859
Failure Code [DY2EKB]1861
Troubleshooting of Electrical System (E-Mode)1863
E-1 Engine Does Not Start (Engine Does Not Crank)1863
E-2 Manual Preheating System Does Not Operate1869
E-3 Automatic Preheating System Does Not Operate1872
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1874
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1876
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1879
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1880
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1881
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1882
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1883
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1884
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1885
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1886
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1887
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation1888
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum1889
E-17 Display of Fuel Gauge is Different from Actual Fuel Level1891
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1892
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1893
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1894
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1896
E-22 Some Areas of Machine Monitor Screen are Not Shown1897
E-23 Function Switch Does Not Operate1898
E-24 Automatic Warm-up System Does Not Work (in Cold Weather)1899
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1900
E-26 Auto-Decelerator is Not Operated or Canceled with Lever1901
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1902
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1903
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1904
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1905
E-31 Alarm Buzzer Cannot be Canceled1907
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position1908
E-33 Service Mode Cannot be Selected1909
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1910
E-35 All Work Equipment, Swing and Travel Do Not Lock1912
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1913
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1916
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor1918
E-39 One-Touch Power Maximizing Function is Not Cancelled1920
E-40 Alarm Does Not Sound During Travel1921
E-41 Alarm Does Not Stop When Machine Stops1923
E-42 Horn Does Not Sound1924
E-43 Horn Does Not Stop1928
E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1930
E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1931
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated1933
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function1934
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function1935
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function1936
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function1937
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1938
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function1939
E-53 “Swing” is Not Shown Correctly with Monitoring Function1940
E-54 “Travel” is Not Shown Correctly with Monitoring Function1941
E-55 Service is Not Shown Correctly with Monitoring Function1942
E-56 Attachment Hydraulic Circuit Cannot be Changed1944
E-57 KOMTRAX System Does Not Operate Correctly1945
E-58 Machine Push-up Function Cannot be Canceled1946
E-59 Machine Push-Up Function Does Not Operate1948
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1949
Information Shown in Troubleshooting Table (H-Mode)1949
System Chart of Hydraulic and Mechanical Systems1950
Failure Mode and Cause Table1952
H-1 All Work Equipment, Swing and Travel Do Not Work1960
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1961
H-3 Fine Control Performance or Response is Unsatisfactory1963
H-4 Unusual Noise is Heard from Around Hydraulic Pump1964
H-5 Engine Speed Drops Largely or Engine Stops1965
H-6 Speed or Power of Boom is Low1967
H-7 Arm Speed or Power is Low1973
H-8 Bucket Speed or Power is Low1978
H-9 Work Equipment Does Not Move in Single Operation1981
H-10 Hydraulic Drift of Boom is Large1982
H-11 Hydraulic Drift of Arm is Large1984
H-12 Hydraulic Drift of Bucket is Large1986
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1987
H-14 Time Lag of Work Equipment is Large1988
H-15 One-Touch Power Maximizing Function Does Not Operate1989
H-16 Machine Push-Up Function Does Not Operate1990
H-17 Attachment Circuit Cannot be Changed1991
H-18 Oil Flow in Attachment Circuit Cannot be Changed1992
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1993
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely1994
H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1995
H-22 Machine Does Not Travel Straight1996
H-23 Machine is Not Steered Correctly or Steering Power is Low1998
H-24 Travel Speed is Low2001
H-25 One of Tracks Does Not Run2003
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2004
H-27 Machine Does Not Swing to Right or Left2005
H-28 Upper Structure Swings Only to Right or Left2006
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left2007
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction2008
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2009
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2010
H-33 Shock is Large When Upper Structure Stops Swing Operation2011
H-34 There is Large Unusual Noise When It Stops Swing Operation2012
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2013
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2014
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2015
H-38 Unusual Noise is Heard from Around Fan2016
Troubleshooting of Engine (S-Mode)2017
Information Shown in Troubleshooting Table (S-Mode)2017
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position2018
S-2 Engine Cranks but No Exhaust Smoke Comes Out2019
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2020
S-4 Engine Startability is Unsatisfactory2021
S-5 Engine Does Not Pick Up Smoothly2023
S-6 Engine Stops During Operation2025
S-7 Engine Runs Rough or is Not Stable2027
S-8 Engine Lacks Power2028
S-9 KDPF Becomes Clogged in a Short Time2030
S-10 Engine Oil Consumption is Excessive2032
S-11 Oil Becomes Dirty Quickly2033
S-1 Fuel Consumption is Excessive2034
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant2035
S-14 Oil Pressure Drops2036
S-15 Fuel Mixes Into Engine Oil2038
S-16 Water Mixes Into Engine Oil (Milky)2039
S-17 Coolant Temperature Increases Too High (Overheating)2040
S-18 Unusual Noise is Heard2041
S-19 Vibration is Excessive2042
S-2 Air Cannot be Bled from Fuel Circuit2043
S-21 Active Regeneration is Done Frequently2044
S-22 Active Regeneration Continues Long2046
S-23 White Smoke is Exhausted During Active Regeneration2047
S-24 DEF Consumption is Excessive2048
S-25 There is Unusual Smell (Irritating Odor)2050
S-26 Foreign Materials Enter DEF (DEF Increases)2051
50 Disassembly and Assembly2053
Table of Contents2054
Precautions Before Work2059
Related Information on Disassembly and Assembly2060
How to Read This Manual2060
Coating Materials List2061
Special Tool List2066
Sketches of Special Tools2078
Engine and Cooling System2084
Remove and Install Supply Pump Assembly2084
How to Remove Supply Pump Assembly2084
How to Install Supply Pump Assembly2090
Remove and Install Injector Assembly2099
How to Remove Injector Assembly2099
How to Install Injector Assembly2105
Remove and Install Fuel Doser Assembly2115
How to Remove Fuel Doser2115
How to Install Fuel Doser2116
Remove and Install Cylinder Head Assembly2118
How to Remove Cylinder Head Assembly2118
How to Install Cylinder Head Assembly2127
Remove and Install EGR Valve Assembly2141
How to Remove EGR Valve Assembly2141
How to Install EGR Valve Assembly2143
Remove and Install EGR Cooler Assembly2145
How to Remove EGR Cooler Assembly2145
How to Install EGR Cooler Assembly2149
Remove and Install Starter Assembly2155
How to Remove Starting Motor Assembly2155
How to Install Starting Motor Assembly2156
Remove and Install Alternator Belt2158
How to Remove Alternator Belt2158
How to Install Alternator Belt2161
Remove and Install Radiator Assembly2166
How to Remove Radiator Assembly2166
How to Install Radiator Assembly2168
Remove and Install Cooling Fan and Fan Motor Assembly2171
How to Remove Cooling Fan and Fan Motor Assembly2171
How to Install Cooling Fan and Fan Motor Assembly2175
Remove and Install Hydraulic Oil Cooler Assembly2180
How to Remove Hydraulic Oil Cooler Assembly2180
How to Install Hydraulic Oil Cooler Assembly2182
Remove and Install Aftercooler Assembly2184
How to Remove Aftercooler Assembly2184
How to Install Aftercooler Assembly2186
Remove and Install Engine and Main Pump Assembly2190
How to Remove Engine and Main Pump Assembly2191
How to Install Engine and Main Pump Assembly2209
Remove and Install Engine Front Oil Seal2228
How to Remove Engine Front Oil Seal2229
How to Install Engine Front Oil Seal2231
Remove and Install Engine Rear Oil Seal2235
How to Remove Engine Rear Oil Seal2236
How to Install Engine Rear Oil Seal2239
Remove and Install Engine Hood Assembly2245
How to Remove Engine Hood Assembly2245
How to Install Engine Hood Assembly2253
Remove and Install Fuel Tank Assembly2264
How to Remove Fuel Tank Assembly2264
How to Install Fuel Tank Assembly2268
Remove and Install DEF Tank Assembly2272
How to Remove DEF Tank Assembly2272
How to Install DEF Tank Assembly2278
Remove and Install DEF Tank Sensor Flange Assembly2283
How to Remove DEF Tank Sensor Flange Assembly2283
How to Install DEF Tank Sensor Flange Assembly2290
Remove and Install DEF Tank Sensor2296
How to Remove DEF Tank Sensor2296
How to Install DEF Tank Sensor2296
Remove and Install DEF Tank Filler Port Filter2303
How to Remove DEF Tank Filler Port Filter2303
How to Install DEF Tank Filler Port Filter2305
Remove and Install KDPF Assembly2308
How to Remove KDPF Assembly2308
How to Install KDPF Assembly2312
Disassemble and Assemble KDPF Assembly2317
How to Disassemble KDPF Assembly2318
How to Assemble KDPF Assembly2323
Remove and Install SCR Assembly2330
How to Remove SCR Assembly2330
How to Install SCR Assembly2333
Remove and Install KDPF and SCR Assembly2337
How to Remove KDPF and SCR Assembly2337
How to Install KDPF and SCR Assembly2342
Remove and Install KDPF and SCR Assembly Bracket2347
How to Remove KDPF and SCR Assembly Bracket2347
How to Install KDPF and SCR Assembly Bracket2352
Remove and Install Bellows Pipe Assembly2361
How to Remove Bellows Pipe Assembly2361
How to Install Bellows Pipe Assembly2363
Remove and Install KCCV Assembly2367
How to Remove KCCV Assembly2367
How to Install KCCV Assembly2368
Remove and Install DEF Mixing Tube2372
How to Remove DEF Mixing Tube2372
How to Install DEF Mixing Tube2377
Remove and Install DEF Injector2383
How to Remove DEF Injector2383
How to Install DEF Injector2387
Remove and Install DEF Pump2392
How to Remove DEF Pump2392
How to Install DEF Pump2394
Remove and Install DEF Hose2395
How to Remove DEF Hose2395
How to Install DEF Hose2400
Remove and Install Air Cleaner Assembly2409
How to Remove Air Cleaner Assembly2409
How to Install Air Cleaner Assembly2410
Remove and Install Air Conditioner Compressor Assembly2413
How to Remove Air Conditioner Compressor Assembly2413
How to Install Air Conditioner Compressor Assembly2416
Remove and Install Air Conditioner Condenser Assembly2420
How to Remove Air Conditioner Condenser Assembly2420
How to Install Air Conditioner Condenser Assembly2421
Power Train2423
Remove and Install Travel Motor and Final Drive Assembly2423
How to Remove Travel Motor and Final Drive Assembly2423
How to Install Travel Motor and Final Drive Assembly2424
Disassemble and Assemble Final Drive Assembly2425
How to Disassemble Final Drive Assembly2425
How to Assemble Final Drive Assembly2430
Remove and Install Swing Motor and Swing Machinery Assembly2436
How to Remove Swing Motor and Swing Machinery Assembly2436
How to Install Swing Motor and Swing Machinery Assembly2437
Disassemble and Assemble Swing Machinery Assembly2439
How to Disassemble Swing Machinery Assembly2439
How to Assemble Swing Machinery Assembly2443
Remove and Install Swing Circle Assembly2449
How to Remove Swing Circle Assembly2449
How to Install Swing Circle Assembly2449
Undercarriage and Frame2451
Separate and Connect Track Assembly2451
How to Separate Track Assembly2451
How to Install Track Assembly2453
Remove and Install Sprocket2456
How to Remove Sprocket2456
How to Install Sprocket2456
Remove and Install Idler and Idler Cushion Assembly2458
How to Remove Idler and Idler Cushion Assembly2458
How to Install Idler and Idler Cushion Assembly2459
Disassemble and Assemble Idler Assembly2461
How to Disassemble Idler Assembly2461
How to Assemble Idler Assembly2463
Disassemble and Assemble Idler Cushion Assembly2468
How to Disassemble Idler Cushion Assembly2469
How to Assemble Idler Cushion Assembly2471
Disassemble and Assemble Track Roller Assembly2474
How to Disassemble Track Roller Assembly2475
How to Assemble Track Roller Assembly2476
Disassemble and Assemble Carrier Roller Assembly2480
How to Disassemble Carrier Roller Assembly2480
How to Assemble Carrier Roller Assembly2482
Remove and Install Revolving Frame Assembly2485
How to Remove Revolving Frame Assembly2485
How to Install Revolving Frame Assembly2487
Remove and Install Counterweight Assembly2490
How to Remove Counterweight Assembly2490
How to Install Counterweight Assembly2491
Hydraulic System2494
Remove and Install Center Swivel Joint Assembly2494
How to Remove Center Swivel Joint Assembly2494
How to Install Center Swivel Joint Assembly2496
Disassemble and Assemble Center Swivel Joint Assembly2498
How to Disassemble Center Swivel Joint Assembly2499
How to Assemble Center Swivel Joint Assembly2499
Remove and Install Hydraulic Tank Assembly2501
How to Remove Hydraulic Tank Assembly2501
How to Install Hydraulic Tank Assembly2506
Remove and Install Main Pump Assembly2512
How to Remove Main Pump Assembly2512
How to Install Main Pump Assembly2516
Remove and Install Control Valve Assembly2522
How to Remove Control Valve Assembly2522
How to Install Control Valve Assembly2527
Disassemble and Assemble Control Valve Assembly2533
How to Replace Pressure Compensation Valve Seal Ring2534
How to Assemble Control Valve Assembly2535
Remove and Install ATT Bypass Solenoid2540
How to Remove ATT Bypass Solenoid2540
How to Install ATT Bypass Solenoid2543
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 Work Equipment Assembly2551
How to Remove Work Equipment Assembly2552
How to Install Work Equipment Assembly2555
Remove and Install Boom Anti-drop Valve Assembly2559
How to Remove Boom Anti-drop Valve Assembly2559
How to Install Boom Anti-drop Valve Assembly2561
Remove and Install Arm Anti-Drop Valve Assembly2562
How to Remove Arm Anti-Drop Valve Assembly2562
How to Install Arm Anti-Drop Valve Assembly2564
Disassemble and Assemble Anti-Drop Valve Assembly2565
How to Disassemble Anti-Drop Valve Assembly2565
How to Assemble Anti-Drop Valve Assembly2565
Disassemble and Assemble Work Equipment Cylinder Assembly2566
How to Disassemble Work Equipment Cylinder Assembly2566
How to Assemble Work Equipment Cylinder Assembly2569
CAB Related Parts2573
Remove and Install Operator Cab Assembly2573
How to Remove Operator Cab Assembly2573
How to Install Operator Cab Assembly2580
Remove and Install Operator Cab Glass (Adhered Glass)2587
How to Remove Operator Cab Glass (Adhered Glass)2589
How to Install Operator Cab Glass (Adhered Glass)2589
Remove and Install Front Window Assembly2599
How to Remove Front Window Assembly2599
How to Install Front Window Assembly2602
Remove and Install Floor Frame Assembly2608
How to Remove Floor Frame Assembly2608
How to Install Floor Frame Assembly2615
Remove and Install Air Conditioner Unit Assembly2623
How to Remove Air Conditioner Unit Assembly2623
How to Install Air Conditioner Unit Assembly2629
Remove and Install Operator Seat2636
How to Remove Operator Seat2636
How to Install Operator Seat2638
How to Remove and Install Seat Belt2641
How to Remove Seat Belt2641
How to Install Seatbelt2642
Remove and Install Work Equipment Control Lever Assembly2643
How to Remove Work Equipment Control Lever Assembly2643
How to Install Work Equipment Control Lever Assembly2649
Remove and Install Front Wiper Assembly2658
How to Remove Front Wiper Assembly2658
How to Install Front Wiper Assembly2663
Electrical System2672
Remove and Install Engine Controller Assembly2672
How to Remove Engine Controller Assembly2672
How to Install Engine Controller Assembly2673
Remove and Install Pump Controller Assembly2675
How to Remove Pump Controller Assembly2675
How to Install Pump Controller Assembly2678
Remove and Install KomVision Controller Assembly2683
How to Remove KomVision Controller Assembly2683
How to Install KomVision Controller Assembly2684
Remove and Install Machine Monitor Assembly2685
How to Remove Machine Monitor Assembly2685
How to Install Machine Monitor Assembly2688
Remove and Install Pump Swash Plate Sensor2692
How to Remove Pump Swash Plate Sensor2692
How to Install Pump Swash Plate Sensor2693
Remove and Install Mass Air Flow and Temperature Sensor2694
How to Remove Mass Air Flow and Temperature Sensor2694
How to Install Mass Air Flow and Temperature Sensor2695
Remove and Install KCCV Crankcase Pressure Sensor2697
How to Remove KCCV Crankcase Pressure Sensor2697
How to Install KCCV Crankcase Pressure Sensor2698
Remove and Install SCR Temperature Sensor2700
How to Remove SCR Temperature Sensor2700
How to Install SCR Temperature Sensor2702
Remove and Install KomVision Camera2704
How to Remove KomVision Camera2704
How to Install KomVision Camera2705
Remove and Install KOMTRAX Terminal Assembly2707
How to Remove KOMTRAX Terminal Assembly2707
How to Install KOMTRAX Terminal Assembly2710
60 Maintenance Standard2713
Table of Contents2714
Engine and Cooling System2715
Maintenance Standard for Engine Mount2715
Maintenance Standard for Cooling System2716
Maintenance Standard for Cooling Fan Pump2717
Maintenance Standard for Servo Valve2718
Maintenance Standard for Cooling Fan Motor2719
Power Train2720
Maintenance Standard for Swing Circle2720
Maintenance Standard for Swing Machinery2721
Maintenance Standard for Final Drive2723
Maintenance Standard for Sprocket2725
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2726
Undercarriage and Frame2727
Maintenance Standard for Track Frame and Idler Cushion2727
Maintenance Standard for Idler2729
Maintenance Standard for Track Roller2731
Maintenance Standard for Carrier Roller2733
Maintenance Standard for Track Shoes2734
Maintenance Standard for Triple Shoes2737
Hydraulic System2738
Maintenance Standard for Main Pump2738
Maintenance Standard for Swing Motor2740
Maintenance Standard for Travel Motor2743
Maintenance Standard for Control Valve2746
Maintenance Standard for Boom Anti-Drop Valve2757
Maintenance Standard for Arm Anti-Drop Valve2759
Maintenance Standard for Work Equipment and Swing PPC Valve2761
Maintenance Standard for Travel PPC Valve2764
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2767
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2768
Maintenance Standard for Solenoid Valve2770
Maintenance Standard for Attachment Circuit Selector Valve2771
Maintenance Standard for Center Swivel Joint2772
Work Equipment2773
Maintenance Standard for Work Equipment Linkage2773
Dimensions of Arm2778
Dimensions of Bucket2780
Maintenance Standard for Boom Cylinder2782
Maintenance Standard for Arm Cylinder2783
Maintenance Standard for Bucket Cylinder2784
80 Appendix2785
Table of Contents2786
Precautions Before Work2788
Air Conditioner System2789
Precautions for Refrigerant2789
Air Conditioner Component2790
Specifications of Air Conditioner2792
Structure and Function of Refrigeration Cycle2793
Outline of Refrigeration Cycle2794
Component Parts of Air Conditioner System2796
Air Conditioner Unit2796
Configuration Diagram of Air Conditioner Unit2796
Function of Air Conditioner Unit2798
Component Parts of Air Conditioner Unit2800
Function of Evaporator as Air Conditioner Unit Component2801
Function of Heater Core as Air Conditioner Unit Component2801
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2801
Function of Servo Motor as Air Conditioner Unit Component2801
Structure of Expansion Valve as Air Conditioner Unit Component2802
Function of Expansion Valve as Air Conditioner Unit Component2802
Operate Expansion Valve as Air Conditioner Unit Component2802
Function of Dual Pressure Switch2803
Air Conditioner Controller2804
Structure of Air Conditioner Controller2804
Compressor2805
Structure of Compressor2805
Specifications of Compressor2805
Function of Compressor2805
Condenser2806
Structure of Condenser2806
Specifications of Condenser2806
Function of Condenser2806
Receiver Drier2807
Structure of Receiver Dryer2807
Specifications of Receiver Dryer2807
Function of Receiver Dryer2807
Air Conditioner Related Sensors2808
Structure of Sunlight Sensor2808
Function of Sunlight Sensor2808
Structure of Outside Temperature Sensor2808
Function of Outside Air Temperature Sensor2808
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2810
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2812
System Diagram of Air Conditioner2814
Input and Output Signals of Air Conditioner Controller2815
Function of Air Conditioner Controller2816
Locations of Air Conditioner Parts and Layout of Connectors2817
Examine Air Leakage (Duct)2821
How to Examine Air Leakage (Duct)2821
Examine Air Conditioner with Self-Diagnosis Function2823
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2824
Examine Vent (Mode) Changeover2825
How to Examine Vent (Mode) Changeover2825
Examine Fresh/Recirc Air Changeover2827
How to Examine Fresh/Recirc Air Changeover2827
Examine Sunlight Sensor2828
How to Examine Sunlight Sensor2828
Examine Refrigerant (Dual) Pressure Switch2829
How to Examine Refrigerant (Dual) Pressure Switch2829
Examine Relay2830
How to Examine Relay2830
Air Conditioner Troubleshooting Chart 12831
Air Conditioner Troubleshooting Chart 22832
Information Shown in Troubleshooting Table2835
Failure Code [879AKA]2836
Failure Code [879AKB]2837
Failure Code [879BKA]2838
Failure Code [879BKB]2840
Failure Code [879CKA]2842
Failure Code [879CKB]2843
Failure Code [879DKZ]2844
Failure Code [879EMC]2846
Failure Code [879FMC]2847
Failure Code [879GKX]2848
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2850
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2852
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2855
A-4 Troubleshooting for Fresh/Recirc Air Changeover2857
Troubleshooting by Gauge Pressure2859
Connect Service Tool2862
How to Connect Service Tool2862
Precautions for Disconnection and Connection of Air Conditioner Piping2864
Handle Compressor Oil2866
90 Circuit Diagrams2869
Table of Contents2870
Hydraulic Circuit Diagram2871
Symbols Used in Hydraulic Circuit Diagram2871
Hydraulic Circuit Diagram (1/2)2875
Hydraulic Circuit Diagram (2/2)2877
Electrical Circuit Diagram2879
Symbols Used in Electric Circuit Diagram2879
Electrical Circuit Diagram (1/8)2883
Electrical Circuit Diagram (2/8)2885
Electrical Circuit Diagram (3/8)2887
Electrical Circuit Diagram (4/8)2889
Electrical Circuit Diagram (5/8)2891
Electrical Circuit Diagram (6/8)2893
Electrical Circuit Diagram (7/8)2895
Electrical Circuit Diagram (8/8)2897
Electrical Circuit Diagram (For Oceania)(1/10)2899
Electrical Circuit Diagram (For Oceania)(2/10)2901
Electrical Circuit Diagram (For Oceania)(3/10)2903
Electrical Circuit Diagram (For Oceania)(4/10)2905
Electrical Circuit Diagram (For Oceania)(5/10)2907
Electrical Circuit Diagram (For Oceania)(6/10)2909
Electrical Circuit Diagram (For Oceania)(7/10)2911
Electrical Circuit Diagram (For Oceania)(8/10)2913
Electrical Circuit Diagram (For Oceania)(9/10)2915
Electrical Circuit Diagram (For Oceania)(10/10)2917
Index2919

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24