Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06731-07 PDF

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Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06731-07 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06731-07 – PDF DOWNLOAD

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

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06731-07 – PDF DOWNLOAD

SERIAL NUMBERS 85416 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and optional parts in this shop manual are not available in some regions. If you
wish to use such items, consult Komatsu.
• Materials and specifications are subject to change without notice.
• Drawings and photos in this shop manual show the typical model. Some of them will possibly show a different
shape from the actual forklift truck.
Composition of Shop Manual
This shop manual contains the necessary technical information for services done in a shop. These are classified
as follows to make the manual easier to use.
00 Index and Foreword
This section explains the index, foreword, safety and basic information.
01 Specification
This section explains the specifications of the forklift truck.
10 Structure and Function
This section explains the structure and function of each system. The “Structure and Operation” section is a useful
reference material for you to understand the structure of each device better. It also is useful to do a troubleshooting.
20 Standard Value Table
This section explains the standard values for new forklift truck and judgement criteria for testing, adjusting, and
troubleshooting. This standard value table is used to give the standard values in testing and adjusting and to
judge parts in troubleshooting.
30 Testing and Adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and methods to
adjust each part. The standard values and judgement criteria for troubleshooting in “Testing and Adjusting” are
given in the standard value table. Use them together.
40 Troubleshooting
This section explains how to find out defective parts when a failure occurs and how to do remedies. The troubleshooting
is divided by failure modes.
50 Disassembly and Assembly
This section explains the special tools and procedures to remove, install, disassemble, and assemble each
component, and the precautions required for safe work. In addition, tightening torques, and quantity and weight
of coating material, oil, grease, and coolant necessary for these works are also shown.
60 Maintenance Standard
This section explains the maintenance standard values of each device. The judgment criteria and remedies for
disassembly and maintenance are shown in the maintenance standard section.
80 Appendix
This chapter explains the items that follow.
• Devices which cannot be classified into sections are explained as others in this section. The structure, operation,
test, adjustment, and troubleshooting for those are explained together.
• This section explains the items, contents and criteria of the special self-imposed inspection.
90 Circuit Diagrams
This section gives hydraulic circuit diagrams and electrical circuit diagrams

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC490LC-11 Shop Manual SEN06731-07 – PDF DOWNLOAD

SERIAL NUMBERS 85416 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC490LC-11 93
Working Range Drawings 95
Working Range: PC490LC-11 95
Specifications 96
Specifications: PC490LC-11 96
Weight Table 99
Weight Table: PC490LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 107
Urea SCR System Diagram 111
Function of Urea SCR System 112
Function of DEF System 112
Inducement Strategy 114
Component Parts of Urea SCR System 128
DEF Mixing Tube 128
SCR Assembly 128
DEF Tank 131
DEF Pump 133
DEF Injector 134
DEF Hose 135
DEF Tank Heating Valve 136
Boot-up System 137
Layout Drawing of Boot-up System 137
System Operating Lamp System 139
System Diagram of System Operating Lamp System 139
Function of Operation Lamp System 139
Battery Isolator 140
Function of Battery Isolator 140
Engine System 141
Layout Drawing of Engine System 141
Specifications of Engine System 142
Function of Engine System 143
Engine Control System 144
System Diagram of Engine Control 144
Function of Engine Control System 145
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
KOMTRAX System 203
System Diagram of KOMTRAX System 203
Function of KOMTRAX System 203
Component Parts of Control System 204
Machine Monitor 204
KOMTRAX Terminal 217
Pump Controller 219
Resistor for PC-EPC Valve 223
CAN Terminating Resistor 223
Engine Controller 225
Fuel Control Dial 231
Fuel Feed Pump 233
Fuel Feed Pump Switch 234
Hydraulic System 235
Layout Drawing of Hydraulic System 235
CLSS 237
Structure of CLSS 237
Operation of Unload Valve and LS Pressure 239
Pump Swash Plate Angle (Oil Flow) Control 240
Pressure Compensation Control 256
Engine and Pump Combined Control System 260
Engine and Pump Combined Control System Diagram 260
Function of Engine and Pump Combined Control System 262
Pump and Valve Control System 267
Pump and Valve Control System Diagram 267
Function of Pump and Valve Control System 268
Component Parts of Hydraulic System 270
Hydraulic Tank 270
Main Pump 272
Control Valve 298
Work Equipment System 361
Layout Drawing of Work Equipment System 361
Structure of Valve Control 366
One-Touch Power Maximizing System 367
System Diagram of One-Touch Power Maximizing System 367
Function of One-Touch Power Maximizing System 368
Machine Push-up System 369
Machine Push-up System Diagram 369
Function of Machine Push-up System 370
PPC Lock System 371
System Diagram of PPC Lock 371
Function of PPC Lock System 371
Work Equipment and Travel Automatic Lock System 372
System Diagram of Lock Lever Automatic Lock System 372
Function of Work Equipment and Travel Automatic Lock System 372
Operation of Lock Lever Automatic Lock System 373
Attachment Oil Flow Adjuster System 374
Attachment Oil Flow Adjuster System Diagram 374
Function of Attachment Oil Flow Adjuster System 375
Component Parts of Work Equipment System 376
Work Equipment and Swing PPC Valve 376
1st-Line Attachment PPC Valve (with EPC Valve) 382
Solenoid Valve 387
Boom Anti-drop Valve 389
Arm Anti-Drop Valve 393
Attachment Circuit Selector Valve 397
Pilot Circuit Accumulator 400
Swing System 401
Layout Drawing of Swing System 401
Swing Control System Diagram 407
Function of Swing Control System 407
Component Parts of Swing System 411
Swing Motor 411
Swing Machinery 422
Swing Circle 424
Travel System 426
Layout Drawing of Travel System 426
System Diagram of Travel Control System 430
Function of Travel Control System 431
Component Parts of Travel System 432
Travel Motor 432
Final Drive 445
Travel PPC Valve 446
Center Swivel Joint 451
Undercarriage and Frame 453
Layout Drawing of Undercarriage 453
Specifications of Undercarriage 453
Work Equipment 454
Structure of Work Equipment 454
Function of Work Equipment 455
Work Equipment Clearance Adjustment Shim 456
Function of Work Equipment Clearance Adjustment Shim 456
Bucket Clearance Adjustment Shim 457
Function of Bucket Clearance Adjustment Shim 457
CAB Related Parts 458
ROPS CAB 458
Structure of ROPS CAB 458
Function of ROPS CAB 458
CAB Mount 459
Structure of CAB Mount 459
Function of CAB Mount 459
CAB Tipping Stopper 460
Structure of CAB Tipping Stopper 460
Function of CAB Tipping Stopper 460
20 Standard Value Table 461
Table of Contents 462
Standard Value Table for Engine 463
Standard Value Table for Engine: PC490LC-11 463
Standard Value Table for Machine 466
Standard Value Table for Machine: PC490LC-11 466
Machine Posture and Procedures to Measure Performance 482
Standard Value Table for Electricity 486
Standard Value Table for Electricity 486
30 Testing and Adjusting 497
Table of Contents 498
Precautions Before Work 501
Related Information on Testing and Adjusting 502
Tools for Testing and Adjusting 502
Sketch of Tools for Testing and Adjusting 510
Engine and Cooling System 512
Examine Engine Speed 512
How to Examine Engine Speed 512
Examine Boost Pressure 515
How to Examine Boost Pressure on Machine Monitor 515
How to Examine Boost Pressure by Testing Tool 516
Examine Exhaust Gas Color 517
How to Examine Exhaust Gas Color with the Handy Smoke Checker 517
How to Examine Exhaust Gas Color with Smoke Meter 518
Examine Mass Air Flow and Temperature Sensor 519
How to Examine Mass Air Flow and Temperature Sensor 519
Examine and Adjust Valve Clearance 521
How to Examine Valve Clearance 521
How to Adjust Valve Clearance 523
Examine Compression Pressure 524
How to Examine Compression Pressure 524
Examine Blowby Pressure 527
How to Examine Blowby Pressure 527
Examine Engine Oil Pressure 529
How to Examine Engine Oil Pressure on Machine Monitor 529
How to Examine Engine Oil Pressure by Testing Tool 529
Examine EGR Valve and VGT Oil Pressure 531
How to Examine EGR Valve and VGT Oil Pressure 531
Examine Fuel Pressure 533
How to Examine Fuel Pressure 533
Examine Fuel Return Rate and Leakage 535
How to Examine Fuel Return Rate and Leakage 535
Bleed Air from Fuel System 538
How to Bleed Air from Fuel System 538
Examine Fuel Circuit for Leakage 540
How to Examine Fuel System for Leakage 540
Handle Cylinder Cut-out Mode Operation 542
Handle No-Injection Cranking Operation 543
Examine and Adjust Air Conditioner Compressor Belt Tension 544
How to Examine Air Conditioner Compressor Belt Tension 544
How to Adjust Air Conditioner Compressor Belt Tension 544
Clean Fuel Doser 546
How to Clean Fuel Doser 546
Write Injector Compensation Value to Engine Controller 548
How to Write Injector Compensation Value 548
Write Correction for Ash in Soot Accumulation to Engine Controller 554
How to Write Correction for Ash in Soot Accumulation to Engine Controller 554
Examine SCR Related Functions 555
Examine DEF Pump Raised Pressure 558
Examine Injection Volume from DEF Injector 561
Examine DEF Line Heater Relay 1 565
Examine DEF Line Heater Relay 2 567
Examine DEF Pump Heater Relay 570
Examine DEF Tank Heater Valve 573
Examine SCR Denitration Efficiency 576
Clean DEF Tank 581
How to Clean DEF Tank 581
Clean DEF Pump 585
How to Clean DEF Pump 585
Power Train 592
Examine Swing Circle Bearing Clearance 592
How to Examine Swing Circle Bearing Clearance 592
Undercarriage and Frame 593
Examine and Adjust Track Tension 593
How to Examine Track Tension 593
How to Adjust Track Tension 593
Hydraulic System 595
Release Remained Pressure in Hydraulic Circuit 595
How to Release Remained Pressure in Hydraulic System 595
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 598
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 599
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 605
Examine Oil Pressure of Control Circuit 609
How to Examine Oil Pressure in Control Circuit 609
Examine and adjust oil pressure in pump PC control circuit 611
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 611
Examine PC-EPC Valve Outlet Pressure 612
How to Adjust Oil Pressure in Pump PC Control Circuit 613
Examine and Adjust Oil Pressure in Pump LS Control Circuit 615
How to Examine LS Differential Pressure with Machine Monitor 615
How to Examine LS Differential Pressure by Testing Tool 616
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 617
How to Examine LS-EPC Valve Outlet Pressure 618
How to Adjust LS Valve 619
Examine Outlet Pressure of Solenoid Valve 620
How to Examine Outlet Pressure of Solenoid Valve 620
Operating Condition of Solenoid Valve 621
Examine PPC Valve Outlet Pressure 623
How to Examine Outlet Pressure in PPC Valve 623
Adjust Play of Work Equipment and Swing PPC Valves 625
How to Adjust Play of Work Equipment and Swing PPC Valves 625
Examine Pump Swash Plate Sensor 626
How to Examine pump swash plate sensor 626
Examine Cooling Fan Speed 627
How to Examine Cooling Fan Speed 627
Examine Oil Pressure in Fan Pump Circuit 628
How to Examine Oil Pressure in Fan Pump Circuit 628
Examine Fan Pump EPC Electric Current 630
How to Examine Fan Pump EPC Electric Current 630
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 631
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 631
Examine Parts Which Cause Hydraulic Drift of Work Equipment 633
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 633
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 633
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 634
Examine Oil Leakage 635
Examine Oil Leakage from Boom Cylinder 635
Examine Oil Leakage of Arm Cylinder 635
Examine Oil Leakage of Bucket Cylinder 636
How to Examine Oil Leakage of Swing Motor 636
How to Examine Oil Leakage of Travel Motor 637
Bleed Air from Hydraulic System 638
How to Bleed Air from Hydraulic System 640
CAB Related Parts 643
Examine CAB Tipping Stopper 643
How to Examine Cab Tipping Stopper 643
How to Adjust Mirrors 644
Procedure to Adjust Machine Left Front Mirror (A) 644
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 645
Procedure to Adjust Machine Right Front Mirror (B) 646
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 647
Procedure to Adjust Machine Right Side Mirror (C) 648
Electrical System 650
Set and Operate Machine Monitor 650
Operator Mode 653
Function to Show Technician Identification Status Screen 654
Function to Show Operator Identification Input Screen 654
Examine Function by LCD (Liquid Crystal Display) 655
Examine Function of Service Meter 655
Usage Limitation and Maintenance Password Change Function 655
Service Mode 658
How to Operate Service Mode 658
How to See Pre-defined Monitoring Information 660
How to Examine Self-Define Monitor Information 667
Abnormality Record Menu 678
How to See Maintenance Record 683
Maintenance Mode Setting 684
How to Set Phone Number Entry 688
Default Menu 689
Diagnostic Tests Menu 697
Adjustment Menu 706
No-Injection Cranking Operation 724
KOMTRAX Settings Menu 725
How to Show Service Message 727
How to Start Up KOMTRAX Terminal 729
Adjust Rearview Camera Angle 734
How to Adjust Rearview Camera Angle 734
Adjust KomVision Camera Angle 737
How to Adjust KomVision Camera Angle 738
Adjust KomVision Related Function 742
Setting of KomVision (Main Setting) 742
Setting of KomVision (Camera Setting) 744
Setting of KomVision (Camera Calibration) 746
KomVision screen – Check 12 m visibility 759
Set Region of Bluetooth(R) Compatible Radio 762
How to Set Region of Bluetooth(R) Compatible Radio 762
Handle Voltage Circuit of Engine Controller 764
Handle Battery Isolator Switch 765
Examine Diodes 766
How to Examine Diodes by Digital Tester 766
How to Examine Diodes by Analog Tester 766
Pm Clinic 767
Pm Clinic Service 767
Pm Clinic Check Sheet 768
40 Troubleshooting 783
Table of Contents 784
Precautions Before Work 794
Related Information to Troubleshooting 795
General Troubleshooting Points 795
Troubleshooting Points for Urea SCR System 796
Sequence of Events in Troubleshooting 810
Checks Before Troubleshooting 812
Inspection Procedure Before Troubleshooting 814
Walk-Around Check 814
Test in Accordance with Testing Procedure 816
Examine Fuel Level and Type 816
Examine for Impure Ingredient in Fuel 817
Examine Fuel Prefilter 817
Examine Water Separator, Drain Water and Sediment 817
Replace Fuel Prefilter Cartridge 818
Examine Fuel Main Filter 819
Examine Engine Oil Level (Oil Quantity in Oil Pan) 820
Examine Coolant Level (Reservoir Tank) 822
Examine Air Cleaner Clogging 822
Clean Outer Element 823
Replace Element 825
Examine Hydraulic Oil Level 826
Examine Hydraulic Oil Strainer 826
Examine Hydraulic Oil Filter 827
Examine Oil Level in Swing Machinery Case 828
Examine Oil Level in Damper Case 829
Examine Oil Level in Final Drive Case 829
Bleed Air from Fuel System 830
Bleed Air from Hydraulic System 830
How to Examine Electric Equipment 830
Preparation for Troubleshooting of Electrical System 836
Procedure for Troubleshooting 837
Symptom and Troubleshooting Numbers 840
Information Shown in Troubleshooting Table 844
Connector List and Layout 846
Connector Contact Connection Table 859
T-Branch Box and T-Branch Adapter Table 899
Fuse Location Table 905
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 908
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 912
Failure Code Table 914
Troubleshooting by Failure Code (Display of Code) 932
Failure Code [6AZ0ZG] 932
Failure Code [879AKA] 934
Failure Code [879AKB] 935
Failure Code [879BKA] 936
Failure Code [879BKB] 938
Failure Code [879CKA] 940
Failure Code [879CKB] 941
Failure Code [879DKZ] 942
Failure Code [879EMC] 944
Failure Code [879FMC] 945
Failure Code [879GKX] 946
Failure Code [989L00] 948
Failure Code [989M00] 949
Failure Code [989N00] 950
Failure Code [A1U0N3] 951
Failure Code [A1U0N4] 953
Failure Code [A900FR] 955
Failure Code [A900N6] 956
Failure Code [A900NY] 957
Failure Code [AA10NX] 958
Failure Code [AB00KE] 960
Failure Code [AQ10N3] 963
Failure Code [AS00N3] 965
Failure Code [AS00R2] 967
Failure Code [AS00R3] 968
Failure Code [AS00R4] 969
Failure Code [AS00R5] 970
Failure Code [AS00R6] 971
Failure Code [AS00ZK] 972
Failure Code [AS10KM] 973
Failure Code [AS10NR] 974
Failure Code [AS10NT] 975
Failure Code [B@BAZG] 976
Failure Code [B@BAZK] 977
Failure Code [B@BCNS] 979
Failure Code [B@BCQA] 980
Failure Code [B@BCZK] 982
Failure Code [B@HANS] 984
Failure Code [CA115] 985
Failure Code [CA122] 986
Failure Code [CA123] 988
Failure Code [CA131] 990
Failure Code [CA132] 992
Failure Code [CA135] 994
Failure Code [CA141] 996
Failure Code [CA144] 998
Failure Code [CA145]1000
Failure Code [CA153]1002
Failure Code [CA154]1005
Failure Code [CA187]1008
Failure Code [CA221]1010
Failure Code [CA222]1012
Failure Code [CA227]1014
Failure Code [CA234]1015
Failure Code [CA238]1016
Failure Code [CA239]1018
Failure Code [CA249]1020
Failure Code [CA256]1022
Failure Code [CA271]1024
Failure Code [CA272]1026
Failure Code [CA273]1027
Failure Code [CA274]1029
Failure Code [CA322]1030
Failure Code [CA323]1032
Failure Code [CA324]1034
Failure Code [CA325]1036
Failure Code [CA331]1038
Failure Code [CA332]1040
Failure Code [CA343]1042
Failure Code [CA351]1043
Failure Code [CA352]1044
Failure Code [CA356]1047
Failure Code [CA357]1049
Failure Code [CA386]1051
Failure Code [CA441]1052
Failure Code [CA442]1054
Failure Code [CA449]1055
Failure Code [CA451]1056
Failure Code [CA452]1058
Failure Code [CA515]1060
Failure Code [CA516]1062
Failure Code [CA553]1064
Failure Code [CA555]1065
Failure Code [CA556]1066
Failure Code [CA559]1067
Failure Code [CA595]1072
Failure Code [CA687]1073
Failure Code [CA689]1075
Failure Code [CA691]1077
Failure Code [CA692]1079
Failure Code [CA697]1081
Failure Code [CA698]1082
Failure Code [CA731]1083
Failure Code [CA778]1084
Failure Code [CA1117]1087
Failure Code [CA1664]1088
Failure Code [CA1669]1091
Failure Code [CA1673]1092
Failure Code [CA1677]1093
Failure Code [CA1678]1094
Failure Code [CA1682]1095
Failure Code [CA1683]1097
Failure Code [CA1684]1099
Failure Code [CA1686]1101
Failure Code [CA1691]1102
Failure Code [CA1694]1105
Failure Code [CA1695]1107
Failure Code [CA1696]1108
Failure Code [CA1712]1110
Failure Code [CA1713]1113
Failure Code [CA1714]1115
Failure Code [CA1715]1116
Failure Code [CA1776]1117
Failure Code [CA1777]1120
Failure Code [CA1843]1123
Failure Code [CA1844]1125
Failure Code [CA1879]1128
Failure Code [CA1881]1131
Failure Code [CA1883]1133
Failure Code [CA1885]1136
Failure Code [CA1887]1138
Failure Code [CA1921]1140
Failure Code [CA1922]1143
Failure Code [CA1923]1148
Failure Code [CA1924]1150
Failure Code [CA1925]1152
Failure Code [CA1927]1154
Failure Code [CA1928]1156
Failure Code [CA1942]1158
Failure Code [CA1963]1159
Failure Code [CA1977]1162
Failure Code [CA1993]1165
Failure Code [CA2185]1168
Failure Code [CA2186]1170
Failure Code [CA2249]1172
Failure Code [CA2265]1173
Failure Code [CA2266]1175
Failure Code [CA2271]1177
Failure Code [CA2272]1179
Failure Code [CA2349]1181
Failure Code [CA2353]1183
Failure Code [CA2357]1185
Failure Code [CA2381]1186
Failure Code [CA2382]1188
Failure Code [CA2383]1190
Failure Code [CA2386]1192
Failure Code [CA2387]1194
Troubleshooting Flowchart1198
Failure Code [CA2555]1199
Failure Code [CA2556]1202
Failure Code [CA2637]1204
Failure Code [CA2639]1206
Failure Code [CA2732]1209
Failure Code [CA2733]1211
Failure Code [CA2741]1213
Failure Code [CA2765]1214
Failure Code [CA2771]1215
Failure Code [CA2777]1221
Failure Code [CA2878]1224
Failure Code [CA2881]1227
Failure Code [CA2976]1230
Failure Code [CA3133]1232
Failure Code [CA3134]1234
Failure Code [CA3135]1236
Failure Code [CA3142]1239
Failure Code [CA3143]1240
Failure Code [CA3144]1241
Failure Code [CA3146]1243
Failure Code [CA3147]1244
Failure Code [CA3148]1245
Failure Code [CA3151]1247
Failure Code [CA3165]1253
Failure Code [CA3167]1255
Failure Code [CA3229]1258
Failure Code [CA3231]1260
Failure Code [CA3232]1262
Failure Code [CA3235]1266
Failure Code [CA3239]1268
Failure Code [CA3241]1271
Failure Code [CA3242]1274
Failure Code [CA3251]1277
Failure Code [CA3253]1279
Failure Code [CA3254]1282
Failure Code [CA3255]1285
Failure Code [CA3256]1289
Failure Code [CA3311]1291
Failure Code [CA3312]1293
Failure Code [CA3313]1296
Failure Code [CA3314]1297
Failure Code [CA3315]1298
Failure Code [CA3316]1301
Failure Code [CA3317]1302
Failure Code [CA3318]1303
Failure Code [CA3319]1305
Failure Code [CA3321]1306
Failure Code [CA3322]1308
Failure Code [CA3419]1311
Failure Code [CA3421]1313
Failure Code [CA3497]1315
Failure Code [CA3498]1316
Failure Code [CA3543]1317
Failure Code [CA3545]1324
Failure Code [CA3547]1326
Failure Code [CA3558]1327
Failure Code [CA3559]1329
Failure Code [CA3562]1331
Failure Code [CA3563]1333
Failure Code [CA3567]1336
Failure Code [CA3568]1339
Failure Code [CA3571]1343
Failure Code [CA3572]1345
Failure Code [CA3574]1347
Failure Code [CA3575]1349
Failure Code [CA3577]1351
Failure Code [CA3578]1353
Failure Code [CA3582]1355
Failure Code [CA3583]1361
Failure Code [CA3596]1363
Failure Code [CA3649]1365
Failure Code [CA3681]1367
Failure Code [CA3682]1372
Failure Code [CA3713]1378
Failure Code [CA3717]1381
Failure Code [CA3718]1382
Failure Code [CA3725]1383
Failure Code [CA3748]1386
Failure Code [CA3751]1388
Failure Code [CA3755]1390
Failure Code [CA3866]1392
Failure Code [CA3867]1396
Failure Code [CA3868]1399
Failure Code [CA3899]1403
Failure Code [CA3911]1405
Failure Code [CA3912]1409
Failure Code [CA3932]1411
Failure Code [CA3933]1413
Failure Code [CA3934]1415
Failure Code [CA3935]1418
Failure Code [CA3936]1420
Failure Code [CA4151]1422
Failure Code [CA4152]1426
Failure Code [CA4155]1430
Failure Code [CA4156]1432
Failure Code [CA4157]1435
Failure Code [CA4158]1437
Failure Code [CA4159]1438
Failure Code [CA4161]1439
Failure Code [CA4162]1442
Failure Code [CA4163]1445
Failure Code [CA4164]1447
Failure Code [CA4165]1449
Failure Code [CA4166]1451
Failure Code [CA4168]1453
Failure Code [CA4169]1456
Failure Code [CA4171]1458
Failure Code [CA4249]1461
Failure Code [CA4251]1463
Failure Code [CA4259]1465
Failure Code [CA4261]1468
Failure Code [CA4277]1471
Failure Code [CA4281]1475
Failure Code [CA4459]1478
Failure Code [CA4461]1480
Failure Code [CA4658]1483
Failure Code [CA4731]1487
Failure Code [CA4732]1488
Failure Code [CA4739]1489
Failure Code [CA4768]1490
Failure Code [CA4769]1492
Failure Code [CA4842]1495
Failure Code [CA4952]1499
Failure Code [CA5115]1501
Failure Code [CA5179]1504
Failure Code [CA5181]1506
Failure Code [CA5383]1508
Failure Code [D110KB]1510
Failure Code [D19JKZ]1512
Failure Code [D811MC]1515
Failure Code [D862KA]1516
Failure Code [D8ALKA]1517
Failure Code [D8ALKB]1519
Failure Code [D8AQKR]1521
Failure Code [DA20MC]1523
Failure Code [DA22KK]1524
Failure Code [DA25KP]1527
Failure Code [DA29KQ]1530
Failure Code [DA2LKA]1532
Failure Code [DA2LKB]1534
Failure Code [DA2QKR]1536
Failure Code [DA2RKR]1539
Failure Code [DAF0MB]1540
Failure Code [DAF0MC]1541
Failure Code [DAF8KB]1542
Failure Code [DAF9KQ]1544
Failure Code [DAFGMC]1545
Failure Code [DAFLKA]1546
Failure Code [DAFLKB]1548
Failure Code [DAFQKR]1550
Failure Code [DAZ9KQ]1551
Failure Code [DAZQKR]1552
Failure Code [DB2QKR]1557
Failure Code [DB2RKR]1562
Failure Code [DDNRKA]1566
Failure Code [DDNRKY]1568
Failure Code [DDNS00]1570
Failure Code [DGH2KA]1572
Failure Code [DGH2KB]1574
Failure Code [DHA4KA]1576
Failure Code [DHAAMA]1578
Failure Code [DHACMA]1580
Failure Code [DHPAMA]1582
Failure Code [DHPBMA]1585
Failure Code [DHS3MA]1588
Failure Code [DHS4MA]1591
Failure Code [DHS8MA]1594
Failure Code [DHS9MA]1597
Failure Code [DHSAMA]1600
Failure Code [DHSBMA]1603
Failure Code [DHSCMA]1606
Failure Code [DHSDMA]1609
Failure Code [DHSFMA]1612
Failure Code [DHSGMA]1615
Failure Code [DHSHMA]1618
Failure Code [DHSJMA]1621
Failure Code [DHSVMA]1624
Failure Code [DKR0MA]1627
Failure Code [DKR1MA]1630
Failure Code [DKULKA]1633
Failure Code [DKULKB]1635
Failure Code [DKULKY]1637
Failure Code [DLM3KA]1639
Failure Code [DLM3KB]1641
Failure Code [DLM3MB]1643
Failure Code [DR21KX]1644
Failure Code [DR31KX]1646
Failure Code [DV20KB]1648
Failure Code [DW43KA]1650
Failure Code [DW43KB]1652
Failure Code [DW43KY]1654
Failure Code [DW45KA]1656
Failure Code [DW45KB]1659
Failure Code [DW45KY]1662
Failure Code [DW4CKY]1664
Failure Code [DW7BKA]1665
Failure Code [DW7BKB]1667
Failure Code [DW7BKY]1669
Failure Code [DW91KA]1670
Failure Code [DW91KB]1672
Failure Code [DW91KY]1674
Failure Code [DWA2KA]1676
Failure Code [DWA2KB]1678
Failure Code [DWA2KY]1680
Failure Code [DWK0KA]1682
Failure Code [DWK0KB]1684
Failure Code [DWK0KY]1686
Failure Code [DWK2KA]1688
Failure Code [DWK2KB]1690
Failure Code [DWK2KY]1692
Failure Code [DWK8KA]1694
Failure Code [DWK8KB]1696
Failure Code [DWK8KY]1698
Failure Code [DX16KA]1700
Failure Code [DX16KB]1702
Failure Code [DXA8KA]1704
Failure Code [DXA8KB]1706
Failure Code [DXA9KA]1708
Failure Code [DXA9KB]1710
Failure Code [DXE0KA]1712
Failure Code [DXE0KB]1714
Failure Code [DXE4KA]1716
Failure Code [DXE4KB]1718
Failure Code [DXE4KY]1720
Failure Code [DXE5KA]1722
Failure Code [DXE5KB]1724
Failure Code [DXE6KA]1726
Failure Code [DXE6KB]1728
Failure Code [DXE7KA]1730
Failure Code [DXE7KB]1732
Failure Code [DXE7KY]1734
Failure Code [DXE8KA]1736
Failure Code [DXE8KB]1738
Failure Code [DXE8KY]1740
Failure Code [DXE9KA]1742
Failure Code [DXE9KB]1744
Failure Code [DXE9KY]1746
Failure Code [DXEAKA]1748
Failure Code [DXEAKB]1750
Failure Code [DXEAKY]1752
Failure Code [DY20KA]1754
Failure Code [DY20MA]1756
Failure Code [DY2CKB]1758
Failure Code [DY2DKB]1761
Failure Code [DY2EKB]1763
Troubleshooting of Electrical System (E-Mode)1765
E-1 Engine Does Not Start (Engine Does Not Crank)1765
E-2 Manual Preheating System Does Not Operate1771
E-3 Automatic Preheating System Does Not Operate1774
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1776
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1778
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1781
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1782
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1783
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1784
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1785
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1786
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1787
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1788
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1789
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation1790
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum1791
E-17 Display of Fuel Gauge is Different from Actual Fuel Level1793
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1794
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1795
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1796
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1798
E-22 Some Areas of Machine Monitor Screen are Not Shown1799
E-23 Function Switch Does Not Operate1800
E-24 Automatic Warm-up System Does Not Work (in Cold Weather)1801
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1802
E-26 Auto-Decelerator is Not Operated or Canceled with Lever1803
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1804
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1805
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1806
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1807
E-31 Alarm Buzzer Cannot be Canceled1809
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position1810
E-33 Service Mode Cannot be Selected1811
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1812
E-35 All Work Equipment, Swing and Travel Do Not Lock1814
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1815
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1818
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor1820
E-39 One-Touch Power Maximizing Function is Not Cancelled1822
E-40 Alarm Does Not Sound During Travel1823
E-41 Alarm Does Not Stop When Machine Stops1825
E-42 Horn Does Not Sound1826
E-43 Horn Does Not Stop1830
E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1832
E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1833
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated1835
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function1836
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function1837
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function1838
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function1839
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1840
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function1841
E-53 “Swing” is Not Shown Correctly with Monitoring Function1842
E-54 “Travel” is Not Shown Correctly with Monitoring Function1843
E-55 Service is Not Shown Correctly with Monitoring Function1844
E-56 Attachment Hydraulic Circuit Cannot be Changed1846
E-57 KOMTRAX System Does Not Operate Correctly1847
E-58 Machine Push-up Function Cannot be Canceled1848
E-59 Machine Push-Up Function Does Not Operate1850
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1851
Information Shown in Troubleshooting Table (H-Mode)1851
System Chart of Hydraulic and Mechanical Systems1852
Failure Mode and Cause Table1854
H-1 All Work Equipment, Swing and Travel Do Not Work1862
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1863
H-3 Fine Control Performance or Response is Unsatisfactory1865
H-4 Unusual Noise is Heard from Around Hydraulic Pump1866
H-5 Engine Speed Drops Largely or Engine Stops1867
H-6 Speed or Power of Boom is Low1869
H-7 Arm Speed or Power is Low1875
H-8 Bucket Speed or Power is Low1880
H-9 Work Equipment Does Not Move in Single Operation1883
H-10 Hydraulic Drift of Boom is Large1884
H-11 Hydraulic Drift of Arm is Large1886
H-12 Hydraulic Drift of Bucket is Large1888
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1889
H-14 Time Lag of Work Equipment is Large1890
H-15 One-Touch Power Maximizing Function Does Not Operate1891
H-16 Machine Push-Up Function Does Not Operate1892
H-17 Attachment Circuit Cannot be Changed1893
H-18 Oil Flow in Attachment Circuit Cannot be Changed1894
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1895
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely1896
H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1897
H-22 Machine Does Not Travel Straight1898
H-23 Machine is Not Steered Correctly or Steering Power is Low1900
H-24 Travel Speed is Low1903
H-25 One of Tracks Does Not Run1905
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1906
H-27 Machine Does Not Swing to Right or Left1907
H-28 Upper Structure Swings Only to Right or Left1908
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left1909
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction1910
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1911
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1912
H-33 Shock is Large When Upper Structure Stops Swing Operation1913
H-34 There is Large Unusual Noise When It Stops Swing Operation1914
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1915
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1916
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)1917
H-38 Unusual Noise is Heard from Around Fan1918
Troubleshooting of Engine (S-Mode)1919
Information Shown in Troubleshooting Table (S-Mode)1919
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1920
S-2 Engine Cranks but No Exhaust Smoke Comes Out1921
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1922
S-4 Engine Startability is Unsatisfactory1923
S-5 Engine Does Not Pick Up Smoothly1925
S-6 Engine Stops During Operation1927
S-7 Engine Runs Rough or is Not Stable1929
S-8 Engine Lacks Power1930
S-9 KDPF Becomes Clogged in a Short Time1932
S-10 Engine Oil Consumption is Excessive1934
S-11 Oil Becomes Dirty Quickly1935
S-12 Fuel Consumption is Excessive1936
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1937
S-14 Oil Pressure Drops1938
S-15 Fuel Mixes Into Engine Oil1940
S-16 Water Mixes Into Engine Oil (Milky)1941
S-17 Coolant Temperature Increases Too High (Overheating)1942
S-18 Unusual Noise is Heard1943
S-19 Vibration is Excessive1944
S-20 Air Cannot be Bled from Fuel Circuit1945
S-21 Active Regeneration is Done Frequently1946
S-22 Active Regeneration Continues Long1948
S-23 White Smoke is Exhausted During Active Regeneration1949
S-24 DEF Consumption is Excessive1950
S-25 There is Unusual Smell (Irritating Odor)1952
S-26 Foreign Materials Enter DEF (DEF Increases)1953
50 Disassembly and Assembly1955
Table of Contents1956
Precautions Before Work1961
Related Information on Disassembly and Assembly1962
How to Read This Manual1962
Coating Materials List1963
Special Tool List1968
Sketches of Special Tools1980
Engine and Cooling System1986
Remove and Install Supply Pump Assembly1986
How to Remove Supply Pump Assembly1986
How to Install Supply Pump Assembly1992
Remove and Install Injector Assembly2001
How to Remove Injector Assembly2001
How to Install Injector Assembly2007
Remove and Install Fuel Doser Assembly2017
How to Remove Fuel Doser2017
How to Install Fuel Doser2018
Remove and Install Cylinder Head Assembly2020
How to Remove Cylinder Head Assembly2021
How to Install Cylinder Head Assembly2030
Remove and Install EGR Valve Assembly2043
How to Remove EGR Valve Assembly2043
How to Install EGR Valve Assembly2045
Remove and Install EGR Cooler Assembly2047
How to Remove EGR Cooler Assembly2047
How to Install EGR Cooler Assembly2051
Remove and Install Starter Assembly2057
How to Remove Starting Motor Assembly2057
How to Install Starting Motor Assembly2058
Remove and Install Alternator Belt2060
How to Remove Alternator Belt2060
How to Install Alternator Belt2063
Remove and Install Radiator Assembly2068
How to Remove Radiator Assembly2068
How to Install Radiator Assembly2070
Remove and Install Cooling Fan and Fan Motor Assembly2073
How to Remove Cooling Fan and Fan Motor Assembly2073
How to Install Cooling Fan and Fan Motor Assembly2077
Remove and Install Hydraulic Oil Cooler Assembly2082
How to Remove Hydraulic Oil Cooler Assembly2082
How to Install Hydraulic Oil Cooler Assembly2084
Remove and Install Aftercooler Assembly2086
How to Remove Aftercooler Assembly2086
How to Install Aftercooler Assembly2088
Remove and Install Engine and Main Pump Assembly2092
How to Remove Engine and Main Pump Assembly2093
How to Install Engine and Main Pump Assembly2111
Remove and Install Engine Front Oil Seal2130
How to Remove Engine Front Oil Seal2131
How to Install Engine Front Oil Seal2133
Remove and Install Engine Rear Oil Seal2137
How to Remove Engine Rear Oil Seal2138
How to Install Engine Rear Oil Seal2141
Remove and Install Engine Hood Assembly2147
How to Remove Engine Hood Assembly2147
How to Install Engine Hood Assembly2155
Remove and Install Fuel Tank Assembly2166
How to Remove Fuel Tank Assembly2166
How to Install Fuel Tank Assembly2170
Remove and Install DEF Tank Assembly2174
How to Remove DEF Tank Assembly2174
How to Install DEF Tank Assembly2180
Remove and Install DEF Tank Sensor Flange Assembly2185
How to Remove DEF Tank Sensor Flange Assembly2185
How to Install DEF Tank Sensor Flange Assembly2192
Remove and Install DEF Tank Sensor2198
How to Remove DEF Tank Sensor2198
How to Install DEF Tank Sensor2198
Remove and Install DEF Tank Filler Port Filter2205
How to Remove DEF Tank Filler Port Filter2205
How to Install DEF Tank Filler Port Filter2207
Remove and Install KDPF Assembly2210
How to Remove KDPF Assembly2210
How to Install KDPF Assembly2214
Disassemble and Assemble KDPF Assembly2219
How to Disassemble KDPF Assembly2220
How to Assemble KDPF Assembly2225
Remove and Install SCR Assembly2232
How to Remove SCR Assembly2232
How to Install SCR Assembly2235
Remove and Install KDPF and SCR Assembly2239
How to Remove KDPF and SCR Assembly2239
How to Install KDPF and SCR Assembly2244
Remove and Install KDPF and SCR Assembly Bracket2249
How to Remove KDPF and SCR Assembly Bracket2249
How to Install KDPF and SCR Assembly Bracket2254
Remove and Install Bellows Pipe Assembly2263
How to Remove Bellows Pipe Assembly2263
How to Install Bellows Pipe Assembly2265
Remove and Install KCCV Assembly2269
How to Remove KCCV Assembly2269
How to Install KCCV Assembly2270
Remove and Install DEF Mixing Tube2274
How to Remove DEF Mixing Tube2274
How to Install DEF Mixing Tube2279
Remove and Install DEF Injector2285
How to Remove DEF Injector2285
How to Install DEF Injector2289
Remove and Install DEF Pump2294
How to Remove DEF Pump2294
How to Install DEF Pump2296
Remove and Install DEF Hose2297
How to Remove DEF Hose2297
How to Install DEF Hose2302
Remove and Install Air Cleaner Assembly2311
How to Remove Air Cleaner Assembly2311
How to Install Air Cleaner Assembly2312
Remove and Install Air Conditioner Compressor Assembly2315
How to Remove Air Conditioner Compressor Assembly2315
How to Install Air Conditioner Compressor Assembly2318
Remove and Install Air Conditioner Condenser Assembly2322
How to Remove Air Conditioner Condenser Assembly2322
How to Install Air Conditioner Condenser Assembly2323
Power Train2325
Remove and Install Travel Motor and Final Drive Assembly2325
How to Remove Travel Motor and Final Drive Assembly2325
How to Install Travel Motor and Final Drive Assembly2326
Disassemble and Assemble Final Drive Assembly2327
How to Disassemble Final Drive Assembly2327
How to Assemble Final Drive Assembly2332
Remove and Install Swing Motor and Swing Machinery Assembly2338
How to Remove Swing Motor and Swing Machinery Assembly2338
How to Install Swing Motor and Swing Machinery Assembly2339
Disassemble and Assemble Swing Machinery Assembly2341
How to Disassemble Swing Machinery Assembly2341
How to Assemble Swing Machinery Assembly2345
Remove and Install Swing Circle Assembly2351
How to Remove Swing Circle Assembly2351
How to Install Swing Circle Assembly2351
Undercarriage and Frame2353
Separate and Connect Track Assembly2353
How to Separate Track Assembly2353
How to Install Track Assembly2355
Remove and Install Sprocket2358
How to Remove Sprocket2358
How to Install Sprocket2358
Remove and Install Idler and Idler Cushion Assembly2360
How to Remove Idler and Idler Cushion Assembly2360
How to Install Idler and Idler Cushion Assembly2361
Disassemble and Assemble Idler Assembly2363
How to Disassemble Idler Assembly2363
How to Assemble Idler Assembly2365
Disassemble and Assemble Idler Cushion Assembly2370
How to Disassemble Idler Cushion Assembly2371
How to Assemble Idler Cushion Assembly2373
Disassemble and Assemble Track Roller Assembly2376
How to Disassemble Track Roller Assembly2377
How to Assemble Track Roller Assembly2378
Disassemble and Assemble Carrier Roller Assembly2382
How to Disassemble Carrier Roller Assembly2382
How to Assemble Carrier Roller Assembly2384
Remove and Install Revolving Frame Assembly2387
How to Remove Revolving Frame Assembly2387
How to Install Revolving Frame Assembly2389
Remove and Install Counterweight Assembly2392
How to Remove Counterweight Assembly2392
How to Install Counterweight Assembly2393
Hydraulic System2395
Remove and Install Center Swivel Joint Assembly2395
How to Remove Center Swivel Joint Assembly2395
How to Install Center Swivel Joint Assembly2397
Disassemble and Assemble Center Swivel Joint Assembly2399
How to Disassemble Center Swivel Joint Assembly2400
How to Assemble Center Swivel Joint Assembly2400
Remove and Install Hydraulic Tank Assembly2402
How to Remove Hydraulic Tank Assembly2402
How to Install Hydraulic Tank Assembly2407
Remove and Install Main Pump Assembly2413
How to Remove Main Pump Assembly2413
How to Install Main Pump Assembly2417
Remove and Install Control Valve Assembly2423
How to Remove Control Valve Assembly2423
How to Install Control Valve Assembly2428
Disassemble and Assemble Control Valve Assembly2434
How to Replace Pressure Compensation Valve Seal Ring2435
How to Assemble Control Valve Assembly2436
Disassemble and Assemble Work Equipment PPC Valve Assembly2441
How to Disassemble Work Equipment PPC Valve Assembly2441
How to Assemble Work Equipment PPC Valve Assembly2442
Disassemble and Assemble Travel PPC Valve Assembly2444
How to Disassemble Travel PPC Valve Assembly2444
How to Assemble Travel PPC Valve Assembly2445
Work Equipment2447
Remove and Install Work Equipment Assembly2447
How to Remove Work Equipment Assembly2448
How to Install Work Equipment Assembly2451
Remove and Install Boom Anti-drop Valve Assembly2455
How to Remove Boom Anti-drop Valve Assembly2455
How to Install Boom Anti-drop Valve Assembly2457
Remove and Install Arm Anti-Drop Valve Assembly2458
How to Remove Arm Anti-Drop Valve Assembly2458
How to Install Arm Anti-Drop Valve Assembly2460
Disassemble and Assemble Anti-Drop Valve Assembly2461
How to Disassemble Anti-Drop Valve Assembly2461
How to Assemble Anti-Drop Valve Assembly2461
Disassemble and Assemble Work Equipment Cylinder Assembly2462
How to Disassemble Work Equipment Cylinder Assembly2462
How to Assemble Work Equipment Cylinder Assembly2465
CAB Related Parts2469
Remove and Install Operator Cab Assembly2469
How to Remove Operator Cab Assembly2469
How to Install Operator Cab Assembly2476
Remove and Install Operator Cab Glass (Adhered Glass)2483
How to Remove Operator Cab Glass (Adhered Glass)2485
How to Install Operator Cab Glass (Adhered Glass)2485
Remove and Install Front Window Assembly2495
How to Remove Front Window Assembly2495
How to Install Front Window Assembly2498
Remove and Install Floor Frame Assembly2504
How to Remove Floor Frame Assembly2505
How to Install Floor Frame Assembly2511
Remove and Install Air Conditioner Unit Assembly2519
How to Remove Air Conditioner Unit Assembly2519
How to Install Air Conditioner Unit Assembly2525
Remove and Install Operator Seat2532
How to Remove Operator Seat2532
How to Install Operator Seat2534
How to Remove and Install Seat Belt2537
How to Remove Seat Belt2537
How to Install Seatbelt2538
Remove and Install Work Equipment Control Lever Assembly2539
How to Remove Work Equipment Control Lever Assembly2539
How to Install Work Equipment Control Lever Assembly2545
Remove and Install Front Wiper Assembly2554
How to Remove Front Wiper Assembly2554
How to Install Front Wiper Assembly2559
Electrical System2568
Remove and Install Engine Controller Assembly2568
How to Remove Engine Controller Assembly2568
How to Install Engine Controller Assembly2569
Remove and Install Pump Controller Assembly2571
How to Remove Pump Controller Assembly2571
How to Install Pump Controller Assembly2574
Remove and Install Machine Monitor Assembly2579
How to Remove Machine Monitor Assembly2579
How to Install Machine Monitor Assembly2582
Remove and Install Pump Swash Plate Sensor2586
How to Remove Pump Swash Plate Sensor2586
How to Install Pump Swash Plate Sensor2587
Remove and Install Mass Air Flow and Temperature Sensor2588
How to Remove Mass Air Flow and Temperature Sensor2588
How to Install Mass Air Flow and Temperature Sensor2589
Remove and Install KCCV Crankcase Pressure Sensor2591
How to Remove KCCV Crankcase Pressure Sensor2591
How to Install KCCV Crankcase Pressure Sensor2592
Remove and Install SCR Temperature Sensor2594
How to Remove SCR Temperature Sensor2594
How to Install SCR Temperature Sensor2596
Remove and Install KOMTRAX Terminal Assembly2598
How to Remove KOMTRAX Terminal Assembly2598
How to Install KOMTRAX Terminal Assembly2601
60 Maintenance Standard2605
Table of Contents2606
Engine and Cooling System2607
Maintenance Standard for Engine Mount2607
Maintenance Standard for Cooling System2608
Maintenance Standard for Cooling Fan Pump2609
Maintenance Standard for Servo Valve2610
Maintenance Standard for Cooling Fan Motor2611
Power Train2612
Maintenance Standard for Swing Circle2612
Maintenance Standard for Swing Machinery2613
Maintenance Standard for Final Drive2615
Maintenance Standard for Sprocket2617
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2618
Undercarriage and Frame2619
Maintenance Standard for Track Frame and Idler Cushion2619
Maintenance Standard for Idler2621
Maintenance Standard for Track Roller2623
Maintenance Standard for Carrier Roller2625
Maintenance Standard for Track Shoes2626
Maintenance Standard for Triple Shoes2629
Hydraulic System2630
Maintenance Standard for Main Pump2630
Maintenance Standard for Swing Motor2632
Maintenance Standard for Travel Motor2635
Maintenance Standard for Control Valve2638
Maintenance Standard for Boom Anti-Drop Valve2649
Maintenance Standard for Arm Anti-Drop Valve2651
Maintenance Standard for Work Equipment and Swing PPC Valve2653
Maintenance Standard for Travel PPC Valve2656
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2659
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2660
Maintenance Standard for Solenoid Valve2662
Maintenance Standard for Attachment Circuit Selector Valve2663
Maintenance Standard for Center Swivel Joint2664
Work Equipment2665
Maintenance Standard for Work Equipment Linkage2665
Dimensions of Arm2670
Dimensions of Bucket2672
Maintenance Standard for Boom Cylinder2674
Maintenance Standard for Arm Cylinder2675
Maintenance Standard for Bucket Cylinder2676
80 Appendix2677
Table of Contents2678
Precautions Before Work2680
Air Conditioner System2681
Precautions for Refrigerant2681
Air Conditioner Component2682
Specifications of Air Conditioner2684
Structure and Function of Refrigeration Cycle2685
Outline of Refrigeration Cycle2686
Component Parts of Air Conditioner System2688
Air Conditioner Unit2688
Configuration Diagram of Air Conditioner Unit2688
Function of Air Conditioner Unit2690
Component Parts of Air Conditioner Unit2692
Function of Evaporator as Air Conditioner Unit Component2693
Function of Heater Core as Air Conditioner Unit Component2693
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2693
Function of Servo Motor as Air Conditioner Unit Component2693
Structure of Expansion Valve as Air Conditioner Unit Component2694
Function of Expansion Valve as Air Conditioner Unit Component2694
Operate Expansion Valve as Air Conditioner Unit Component2694
Function of Dual Pressure Switch2695
Air Conditioner Controller2696
Structure of Air Conditioner Controller2696
Compressor2697
Structure of Compressor2697
Specifications of Compressor2697
Function of Compressor2697
Condenser2698
Structure of Condenser2698
Specifications of Condenser2698
Function of Condenser2698
Receiver Drier2699
Structure of Receiver Dryer2699
Specifications of Receiver Dryer2699
Function of Receiver Dryer2699
Air Conditioner Related Sensors2700
Structure of Sunlight Sensor2700
Function of Sunlight Sensor2700
Structure of Outside Temperature Sensor2700
Function of Outside Air Temperature Sensor2700
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2702
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2704
System Diagram of Air Conditioner2706
Input and Output Signals of Air Conditioner Controller2707
Function of Air Conditioner Controller2708
Locations of Air Conditioner Parts and Layout of Connectors2709
Examine Air Leakage (Duct)2713
How to Examine Air Leakage (Duct)2713
Examine Air Conditioner with Self-Diagnosis Function2715
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2716
Examine Vent (Mode) Changeover2717
How to Examine Vent (Mode) Changeover2717
Examine Fresh/Recirc Air Changeover2719
How to Examine Fresh/Recirc Air Changeover2719
Examine Sunlight Sensor2720
How to Examine Sunlight Sensor2720
Examine Refrigerant (Dual) Pressure Switch2721
How to Examine Refrigerant (Dual) Pressure Switch2721
Examine Relay2722
How to Examine Relay2722
Air Conditioner Troubleshooting Chart 12723
Air Conditioner Troubleshooting Chart 22724
Information Shown in Troubleshooting Table2727
Failure Code [879AKA]2728
Failure Code [879AKB]2729
Failure Code [879BKA]2730
Failure Code [879BKB]2732
Failure Code [879CKA]2734
Failure Code [879CKB]2735
Failure Code [879DKZ]2736
Failure Code [879EMC]2738
Failure Code [879FMC]2739
Failure Code [879GKX]2740
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2742
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2744
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2747
A-4 Troubleshooting for Fresh/Recirc Air Changeover2749
Troubleshooting by Gauge Pressure2751
Connect Service Tool2754
How to Connect Service Tool2754
Precautions for Disconnection and Connection of Air Conditioner Piping2756
Handle Compressor Oil2758
90 Circuit Diagrams2761
Table of Contents2762
Hydraulic Circuit Diagram2763
Symbols Used in Hydraulic Circuit Diagram2763
Hydraulic Circuit Diagram (1/3)2767
Hydraulic Circuit Diagram (2/3)2769
Hydraulic Circuit Diagram (3/3)2771
Electrical Circuit Diagram2773
Symbols Used in Electric Circuit Diagram2773
Electrical Circuit Diagram (For Oceania)(1/10)2777
Electrical Circuit Diagram (For Oceania)(2/10)2779
Electrical Circuit Diagram (For Oceania)(3/10)2781
Electrical Circuit Diagram (For Oceania)(4/10)2783
Electrical Circuit Diagram (For Oceania)(5/10)2785
Electrical Circuit Diagram (For Oceania)(6/10)2787
Electrical Circuit Diagram (For Oceania)(7/10)2789
Electrical Circuit Diagram (For Oceania)(8/10)2791
Electrical Circuit Diagram (For Oceania)(9/10)2793
Electrical Circuit Diagram (For Oceania)(10/10)2795
Index2797

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24