Komatsu HYDRAULIC EXCAVATOR PC650LC-11 Shop Manual SEN06603-19 PDF

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Komatsu HYDRAULIC EXCAVATOR PC650LC-11 Shop Manual SEN06603-19 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC650LC-11 Shop Manual SEN06603-19 – PDF DOWNLOAD

Language : English
Pages :2850
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC650LC-11 Shop Manual SEN06603-19 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
00 Index and Foreword How to Read the Shop Manual
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC650LC-11 Shop Manual SEN06603-19 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 22
Foreword, Safety, Basic Information 25
How to Read the Shop Manual 25
Safety Notice for Operation 27
Precautions to Prevent Fire 35
Procedures If Fire Occurs 37
Precautions for Disposing of Waste Materials 38
Procedures for Exhaust Gas Regulations 39
Precautions for DEF 40
General Character and Precautions for Handling 40
Precautions for Adding 40
Precautions for Storage 40
Precautions for Fire Hazard and Leakage 40
Other Precautions 40
Store DEF 41
Precautions When You Handle Hydraulic Equipment 42
Precautions When You Disconnect and Connect Pipings 45
Precautions When You Handle Electrical Equipment 52
Precautions When You Handle Fuel System Equipment 54
Precautions When You Handle Intake System Equipment 55
Practical Use of KOMTRAX 56
Disconnect and Connect Push-Pull Type Coupler 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 59
Precautions for Disconnection and Connection of Connectors 61
How to Disconnect and Connect Deutsch Connector 65
How to Disconnect and Connect Slide Lock Type Connector 66
How to Disconnect and Connect Connector with Lock to Pull 68
How to Disconnect and Connect Connector with Lock to Push 69
How to Disconnect and Connect Connector with Housing to Rotate 71
How to Read the Codes for Electric Cable 72
Explanation of Terms for Maintenance Standard 76
Standard Tightening Torque Table 79
Conversion Table 86
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC650LC-11 93
Working Range Drawings 95
Working Range: PC650LC-11 95
Specifications 96
Specifications: PC650LC-11 96
Weight Table 99
Weight Table: PC650LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 108
Layout Drawing of Urea SCR System 108
Urea SCR System Diagram 113
Function of Urea SCR System 114
Function of DEF System 114
Inducement Strategy 116
Component Parts of Urea SCR System 123
DEF Mixing Tube 123
SCR Assembly 124
DEF Tank 126
DEF Pump 128
DEF Injector 129
DEF Hose 130
DEF Tank Heating Valve 131
Boot-up System 132
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 132
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 133
System Operating Lamp System 134
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 134
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 134
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 134
Function of System Operating Lamp System (Machine with Gateway Function Controller) 135
Battery Disconnect Switch 137
Function of Battery Disconnect Switch 137
Engine System 138
Layout Drawing of Engine System 138
Function of Engine System 139
Engine Control System 140
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 140
System Diagram of Engine Control System (Machine with Gateway Function Controller) 140
Function of Engine Control System (Machine with KOMTRAX Terminal) 141
Function of Engine Control System (Machine with Gateway Function Controller) 143
Auto-Deceleration System 146
System Diagram of Auto-Deceleration System 146
Function of Auto-Deceleration System 146
Operation of Auto-Deceleration System 147
Automatic Low Idle System 148
Automatic Low Idle System Diagram 148
Function of Automatic Low Idle System 148
Operation of Automatic Low Idle System 149
Engine Automatic Warm-up System 150
System Diagram of Engine Automatic Warm-up System 150
Function of Engine Automatic Warm-up System 152
Overheat Prevention System 153
Overheat Prevention System Diagram 153
Function of Overheat Prevention System 154
Turbocharger Protection System 155
System Diagram of Turbocharger Protection System 155
Function of Turbocharger Protection System 156
Automatic Idle Stop System 157
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 157
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 157
Function of Automatic Idle Stop System 158
Component Parts of Engine System 161
PTO 161
VGT 162
EGR System 166
EGR Valve 169
EGR Cooler 171
KCCV System 172
KCCV Ventilator 174
KDPF 176
Cooling System 180
Layout Drawing of Cooling System 180
Specifications of Cooling System 181
Fan Speed Control System of Hydraulic Fan 182
Fan Speed Control System Diagram of Hydraulic Fan 182
Function of Fan Speed Control System of Hydraulic Fan 183
Engine Output Control System of Hydraulic Fan 184
Engine Output Control System Diagram of Hydraulic Fan 184
Function of Engine Output Control System of Hydraulic Fan 184
Fan Reverse Rotation System of Hydraulic Fan 186
Fan Reverse Rotation System Diagram of Hydraulic Fan 186
Function of Fan Reverse Rotation System of Hydraulic Fan 186
Component Parts of Cooling System 187
Cooling Fan Pump 187
Cooling Fan Motor 195
Control System 202
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 202
Layout Drawing of Control System (Machine with Gateway Function Controller) 204
Machine Monitor System 206
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 206
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 207
Function of Machine Monitor System 208
KomVision System 209
Layout Drawing of KomVision System 209
System Diagram of KomVision System 211
Function of KomVision System 212
KOMTRAX System 214
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 214
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 214
Function of KOMTRAX System 215
Component Parts of Control System 216
Machine Monitor 216
KomVision Controller 231
KomVision Camera 235
KOMTRAX Terminal 236
Gateway Function Controller 238
Communication Terminal 241
Pump Controller 243
Resistor for TVC Valve 248
CAN Terminating Resistor 249
Engine Controller 250
Fuel Control Dial 257
Fuel Feed Pump 259
Fuel Feed Pump Switch 260
Hydraulic System 261
Layout Drawing of Hydraulic System 261
OLSS 264
Structure of OLSS 264
Function of OLSS 264
Pump Swash Plate Angle (Oil Flow) Control 266
Engine and Pump Combined Control System 277
Engine and Pump Combined Control System Diagram 277
Function of Engine and Pump Combined Control System 279
Component Parts of Hydraulic System 282
Hydraulic Tank 282
Main Pump 284
Control Valve 312
Variable Back Pressure Valve 333
Work Equipment System 336
Layout Drawing of Work Equipment System 336
One-Touch Power Maximizing System 342
System Diagram of One-Touch Power Maximizing System 342
Function of One-Touch Power Maximizing System 343
Machine Push-up System 344
Machine Push-up System Diagram 344
Function of Machine Push-up System 345
Boom Shockless Control Function 346
Boom Shockless Control Function System Diagram 346
Operation of Boom Shockless Control Function 346
PPC Lock System 347
System Diagram of PPC Lock 347
Function of PPC Lock System 347
Work Equipment and Travel Automatic Lock System 348
System Diagram of Lock Lever Automatic Lock System 348
Function of Work Equipment and Travel Automatic Lock System 348
Operation of Lock Lever Automatic Lock System 349
Component Parts of Work Equipment System 350
Work Equipment and Swing PPC Valve 350
1st-Line Attachment PPC Valve 355
PPC Shuttle Valve 357
Solenoid Valve 358
Pilot Circuit Accumulator 361
Swing System 362
Layout Drawing of Swing System 362
Swing Control System Diagram 365
Function of Swing Control System 366
Component Parts of Swing System 369
Swing Motor 369
Swing Machinery 381
Swing Circle 383
Travel System 384
Layout Drawing of Travel System 384
System Diagram of Travel Control System 388
Function of Travel Control System 390
Component Parts of Travel System 391
Travel Motor 391
Final Drive 404
Travel PPC Valve 406
Center Swivel Joint 410
Undercarriage and Frame 412
Layout Drawing of Undercarriage 412
Specifications of Undercarriage 412
Work Equipment 413
Structure of Work Equipment 413
Function of Work Equipment 414
Work Equipment Clearance Adjustment Shim 415
Function of Work Equipment Clearance Adjustment Shim 415
Bucket Clearance Adjustment Shim 416
Function of Bucket Clearance Adjustment Shim 416
CAB Related Parts 417
CAB 417
Structure of CAB 417
CAB Mount 418
Structure of CAB Mount 418
Function of CAB Mount 418
CAB Tipping Stopper 419
Structure of CAB Tipping Stopper 419
Function of CAB Tipping Stopper 419
20 Standard Value Table 421
Table of Contents 422
Standard Value Table for Engine 423
Standard Value Table for Engine: PC650LC-11 423
Standard Value Table for Machine 428
Standard Value Table for Machine: PC650LC-11 428
Machine Posture and Procedures to Measure Performance 445
30 Testing and Adjusting 449
Table of Contents 450
Precautions Before Work 453
Related Information on Testing and Adjusting 454
Tools for Testing and Adjusting 454
Sketch of Tools for Testing and Adjusting 463
Engine and Cooling System 465
Examine Engine Speed 465
How to Examine Engine Speed 465
Examine Boost Pressure 468
How to Examine Boost Pressure on Machine Monitor 468
How to Examine Boost Pressure by Testing Tool 469
Examine Exhaust Gas Temperature 470
How to Examine Exhaust Gas Temperature 470
Examine Exhaust Gas Color 472
How to Examine Exhaust Gas Color with the Handy Smoke Checker 472
How to Examine Exhaust Gas Color with Smoke Meter 473
Examine Mass Air Flow and Temperature Sensor 475
How to Examine Mass Air Flow and Temperature Sensor 475
Examine and Adjust Valve Clearance 477
How to Examine Valve Clearance 477
How to Adjust Valve Clearance 478
Examine Compression Pressure 480
How to Examine Compression Pressure 480
Examine Blowby Pressure 483
How to Examine Blowby Pressure 483
Examine Engine Oil Pressure 485
How to Examine Engine Oil Pressure on Machine Monitor 485
How to Examine Engine Oil Pressure by Testing Tool 485
Examine EGR Valve and VGT Oil Pressure 487
How to Examine EGR Valve and VGT Oil Pressure 487
Examine Fuel Pressure 489
How to Examine Fuel Pressure 489
Examine Fuel Return Rate and Leakage 491
How to Examine Fuel Return Rate and Leakage 491
Bleed Air from Fuel System 494
How to Bleed Air from Fuel System 494
Examine Fuel Circuit for Leakage 496
How to Examine Fuel System for Leakage 496
Handle Cylinder Cut-out Mode Operation 498
Handle No-Injection Cranking Operation 499
Examine and Adjust Air Conditioner Compressor Belt Tension 500
How to Examine Air Conditioner Compressor Belt 500
Clean Fuel Doser 501
How to Clean Fuel Doser 501
Write Injector Compensation Value to Engine Controller 503
How to Write Injector Compensation Value 503
Write Correction for Ash in Soot Accumulation to Engine Controller 509
How to Write Correction for Ash in Soot Accumulation to Engine Controller 509
Examine SCR Related Functions 510
Examine DEF Pump Raised Pressure 514
Examine Injection Volume from DEF Injector 517
Examine DEF Line Heater Relay 1 522
Examine DEF Line Heater Relay 2 526
Examine DEF Pump Heater Relay 529
Examine DEF Tank Heater Valve 532
Examine SCR Denitration Efficiency 535
Clean DEF Tank 539
How to Clean DEF Tank 539
Clean DEF Pump 543
How to Clean DEF Pump 543
Power Train 549
Examine Swing Circle Bearing Clearance 549
How to Examine Swing Circle Bearing Clearance 549
Undercarriage and Frame 550
Examine and Adjust Track Tension 550
How to Examine Track Tension 550
How to Adjust Track Tension 550
Hydraulic System 552
Release Remained Pressure in Hydraulic Circuit 552
How to Release Remained Pressure in Hydraulic System 552
How to Release Remained Pressure from Swing Motor Circuit 561
How to Release Remained Pressure from Travel Motor Circuit 561
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 562
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 565
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 573
Examine and Adjust Oil Pressure in Control Circuit 577
How to Examine Oil Pressure in Control Circuit 577
How to Adjust Oil Pressure in Control Circuit 578
Examine and Adjust Piston Pump Control Oil Pressure 579
How to Examine TVC Valve Outlet Pressure 579
How to Examine CO and NC Valve Outlet Pressure 580
How to Examine Jet Sensor Outlet Differential Pressure 581
How to Adjust TVC Valve 583
How to Adjust CO and NC Valve 584
How to Adjust Jet Sensor 585
Examine Servo Piston Stroke 586
How to Examine Servo Piston Stroke 586
Examine Outlet Pressure of Solenoid Valve 588
How to Examine Outlet Pressure of Solenoid Valve 588
Operating Condition of Solenoid Valve 589
Examine PPC Valve Outlet Pressure 592
How to Examine Outlet Pressure in PPC Valve 592
Examine PPC Shuttle Valve Outlet Pressure 594
How to Examine PPC Shuttle Valve Outlet Pressure 594
Adjust Play of Work Equipment and Swing PPC Valves 597
How to Adjust Play of Work Equipment and Swing PPC Valves 597
Examine and Adjust Travel Deviation 598
How to Examine Travel Deviation 598
How to Adjust Travel Deviation 598
Examine Cooling Fan Speed 600
How to Examine Cooling Fan Speed 600
Examine Oil Pressure in Fan Pump Circuit 601
How to Examine Oil Pressure in Fan Pump Circuit 601
Examine Fan Pump EPC Electric Current 602
How to Examine Fan Pump EPC Electric Current 602
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 603
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 603
Examine Parts Which Cause Hydraulic Drift of Work Equipment 604
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 604
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 604
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 605
Examine Oil Leakage 606
How to Examine Oil Leakage from Boom Cylinder 606
How to Examine Oil Leakage from Arm Cylinder 607
How to Examine Oil Leakage from Bucket Cylinder 607
How to Examine Oil Leakage from Swing Motor 608
How to Examine Oil Leakage from Travel Motor 608
How to Examine Oil Leakage of Swivel Joint 609
Bleed Air from Hydraulic System 611
How to Bleed Air from Hydraulic System 612
CAB Related Parts 615
Examine CAB Tipping Stopper 615
How to Examine Cab Tipping Stopper 615
How to Adjust Mirrors 616
Procedure to Adjust Machine Left Front Mirror (A) 616
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 617
Procedure to Adjust Machine Right Front Mirror (B) 618
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 618
Electrical System 620
Set and Operate Machine Monitor 620
Operator Mode 624
Function to Show Technician Identification Status Screen 624
Function to Show Operator Identification Input Screen 624
Examine Function by LCD (Liquid Crystal Display) 625
Examine Function of Service Meter 625
Usage Limitation and Maintenance Password Change Function 625
Service Mode 628
How to Operate Service Mode 628
How to See Pre-defined Monitoring Information 629
How to Examine Self-Define Monitor Information 636
Abnormality Record Menu 647
How to See Maintenance Record 651
Maintenance Mode Setting 652
How to Set Phone Number Entry 656
Default Menu 658
Diagnostic Tests Menu 664
Adjustment Menu 674
No-Injection Cranking Operation 677
KOMTRAX Settings Menu 679
How to Show Service Message 681
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 683
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 688
Adjust Rearview Camera Angle 693
How to Adjust Rearview Camera Angle 693
Adjust KomVision Camera Angle 695
How to Adjust KomVision Camera Angle 696
Adjust KomVision Related Function 698
Setting of KomVision (Main Setting) 699
Setting of KomVision (Camera Setting) 701
Setting of KomVision (Camera Calibration) 704
KomVision screen – Check 12 m visibility 717
Set Region of Bluetooth(R) Compatible Radio 720
How to Set Region of Bluetooth(R) Compatible Radio 720
Handle Voltage Circuit of Engine Controller 722
Handle Battery Disconnect Switch 723
Examine Diodes 724
How to Examine Diodes by Digital Tester 724
How to Examine Diodes by Analog Tester 724
Pm Clinic 725
Pm Clinic Service 725
Pm Clinic Check Sheet: PC650LC-11 729
40 Troubleshooting 745
Table of Contents 746
Precautions Before Work 757
Related Information to Troubleshooting 758
General Troubleshooting Points 758
Troubleshooting Points for Urea SCR System 759
Sequence of Events in Troubleshooting 773
Checks Before Troubleshooting 775
Inspection Procedure Before Troubleshooting 777
Walk-Around Check 777
Test in Accordance with Testing Procedure 779
Examine Fuel Level and Type 779
Examine for Impure Ingredient in Fuel 780
Examine Fuel Prefilter 780
Examine Water Separator, Drain Water and Sediment 780
Replace Fuel Prefilter Cartridge 781
Examine Fuel Main Filter 782
Examine Engine Oil Level (Oil Quantity in Oil Pan) 783
Examine Coolant Level (Reservoir Tank) 785
Examine Air Cleaner Clogging 785
Clean Outer Element 785
Replace Element 788
Examine Hydraulic Oil Level 788
Examine Hydraulic Oil Strainer 790
Examine Hydraulic Oil Filter 790
Examine Oil Level in Swing Machinery Case 791
Examine Oil Level in PTO Case 792
Examine PTO Lubrication Filter Strainer 792
Examine Oil Level in Final Drive Case 793
Bleed Air from Fuel System 793
Bleed Air from Hydraulic System 794
How to Examine Electric Equipment 794
Preparation for Troubleshooting of Electrical System 800
Preparation for Troubleshooting of Machine Monitor 800
Preparation for Troubleshooting of Engine Controller 800
Preparation for Troubleshooting of Pump Controller 800
Preparation for Troubleshooting of KOMTRAX Terminal 801
Preparation for Troubleshooting of Gateway Function Controller 801
How to Disconnect and Connect Connector with a Special Lock 804
Procedure for Troubleshooting 809
Symptom and Troubleshooting Numbers 812
Information Shown in Troubleshooting Table 816
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 818
Connector List and Layout 821
Connector Contact Connection Table 836
T-Branch Box and T-Branch Adapter Table 876
Fuse Location Table 882
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 885
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 889
Failure Code Table 891
Troubleshooting by Failure Code (Display of Code) 910
Failure Code [879AKA] 910
Failure Code [879AKB] 911
Failure Code [879BKA] 912
Failure Code [879BKB] 914
Failure Code [879CKA] 916
Failure Code [879CKB] 917
Failure Code [879DKZ] 918
Failure Code [879EMC] 920
Failure Code [879FMC] 921
Failure Code [879GKX] 922
Failure Code [989L00] 924
Failure Code [989M00] 925
Failure Code [989N00] 926
Failure Code [A1U0N3] 927
Failure Code [A1U0N4] 929
Failure Code [A900FR] 931
Failure Code [A900N6] 932
Failure Code [A900NY] 933
Failure Code [AA10NX] 934
Failure Code [AB00KE] 936
Failure Code [AQ10N3] 938
Failure Code [AS00N3] 940
Failure Code [AS00R2] 942
Failure Code [AS00R3] 943
Failure Code [AS00R4] 944
Failure Code [AS00R5] 945
Failure Code [AS00R6] 946
Failure Code [AS00ZK] 947
Failure Code [AS10KM] 948
Failure Code [AS10NR] 949
Failure Code [AS10NT] 950
Failure Code [B@BAZG] 951
Failure Code [B@BAZK] 952
Failure Code [B@BCNS] 954
Failure Code [B@BCQA] 955
Failure Code [B@BCZK] 957
Failure Code [B@HANS] 959
Failure Code [CA115] 960
Failure Code [CA122] 961
Failure Code [CA123] 963
Failure Code [CA131] 965
Failure Code [CA132] 967
Failure Code [CA135] 969
Failure Code [CA141] 971
Failure Code [CA144] 973
Failure Code [CA145] 975
Failure Code [CA153] 977
Failure Code [CA154] 980
Failure Code [CA187] 983
Failure Code [CA221] 985
Failure Code [CA222] 987
Failure Code [CA227] 989
Failure Code [CA234] 990
Failure Code [CA238] 991
Failure Code [CA239] 993
Failure Code [CA249] 995
Failure Code [CA256] 997
Failure Code [CA271] 999
Failure Code [CA272]1001
Failure Code [CA273]1002
Failure Code [CA274]1004
Failure Code [CA322]1005
Failure Code [CA323]1007
Failure Code [CA324]1009
Failure Code [CA325]1011
Failure Code [CA331]1013
Failure Code [CA332]1015
Failure Code [CA343]1017
Failure Code [CA351]1018
Failure Code [CA352]1019
Failure Code [CA356]1022
Failure Code [CA357]1024
Failure Code [CA386]1026
Failure Code [CA441]1027
Failure Code [CA442]1029
Failure Code [CA449]1030
Failure Code [CA451]1031
Failure Code [CA452]1033
Failure Code [CA515]1035
Failure Code [CA516]1037
Failure Code [CA553]1039
Failure Code [CA555]1040
Failure Code [CA556]1041
Failure Code [CA559]1042
Failure Code [CA595]1047
Failure Code [CA687]1048
Failure Code [CA689]1050
Failure Code [CA691]1052
Failure Code [CA692]1054
Failure Code [CA697]1056
Failure Code [CA698]1057
Failure Code [CA731]1058
Failure Code [CA778]1059
Failure Code [CA1117]1062
Failure Code [CA1664]1063
Failure Code [CA1669]1067
Failure Code [CA1673]1068
Failure Code [CA1677]1069
Failure Code [CA1678]1070
Failure Code [CA1682]1071
Failure Code [CA1683]1073
Failure Code [CA1684]1075
Failure Code [CA1686]1077
Failure Code [CA1691]1078
Failure Code [CA1694]1081
Failure Code [CA1695]1083
Failure Code [CA1696]1084
Failure Code [CA1712]1086
Failure Code [CA1713]1089
Failure Code [CA1714]1091
Failure Code [CA1715]1092
Failure Code [CA1776]1093
Failure Code [CA1777]1096
Failure Code [CA1843]1099
Failure Code [CA1844]1101
Failure Code [CA1879]1104
Failure Code [CA1881]1107
Failure Code [CA1883]1109
Failure Code [CA1885]1113
Failure Code [CA1887]1115
Failure Code [CA1921]1117
Failure Code [CA1922]1120
Failure Code [CA1923]1125
Failure Code [CA1924]1127
Failure Code [CA1925]1129
Failure Code [CA1927]1131
Failure Code [CA1928]1133
Failure Code [CA1942]1135
Failure Code [CA1963]1136
Failure Code [CA1977]1140
Failure Code [CA1993]1143
Failure Code [CA2185]1146
Failure Code [CA2186]1148
Failure Code [CA2249]1150
Failure Code [CA2265]1151
Failure Code [CA2266]1153
Failure Code [CA2271]1155
Failure Code [CA2272]1157
Failure Code [CA2349]1159
Failure Code [CA2353]1161
Failure Code [CA2357]1163
Failure Code [CA2381]1164
Failure Code [CA2382]1166
Failure Code [CA2383]1168
Failure Code [CA2386]1170
Failure Code [CA2387]1172
Troubleshooting Flowchart1176
Failure Code [CA2555]1177
Failure Code [CA2556]1179
Failure Code [CA2637]1181
Failure Code [CA2639]1183
Failure Code [CA2732]1185
Failure Code [CA2733]1187
Failure Code [CA2741]1189
Failure Code [CA2765]1190
Failure Code [CA2771]1191
Failure Code [CA2777]1197
Failure Code [CA2878]1200
Failure Code [CA2881]1203
Failure Code [CA2976]1206
Failure Code [CA3133]1208
Failure Code [CA3134]1210
Failure Code [CA3135]1212
Failure Code [CA3142]1215
Failure Code [CA3143]1216
Failure Code [CA3144]1217
Failure Code [CA3146]1219
Failure Code [CA3147]1220
Failure Code [CA3148]1221
Failure Code [CA3151]1223
Failure Code [CA3165]1228
Failure Code [CA3167]1231
Failure Code [CA3229]1235
Failure Code [CA3231]1238
Failure Code [CA3232]1241
Failure Code [CA3235]1246
Failure Code [CA3239]1248
Failure Code [CA3241]1251
Failure Code [CA3242]1254
Failure Code [CA3251]1257
Failure Code [CA3253]1261
Failure Code [CA3254]1267
Failure Code [CA3255]1271
Failure Code [CA3256]1274
Failure Code [CA3311]1277
Failure Code [CA3312]1280
Failure Code [CA3313]1283
Failure Code [CA3314]1284
Failure Code [CA3315]1285
Failure Code [CA3316]1288
Failure Code [CA3317]1289
Failure Code [CA3318]1290
Failure Code [CA3319]1293
Failure Code [CA3321]1294
Failure Code [CA3322]1295
Failure Code [CA3419]1298
Failure Code [CA3421]1300
Failure Code [CA3497]1302
Failure Code [CA3498]1303
Failure Code [CA3543]1304
Failure Code [CA3545]1309
Failure Code [CA3547]1311
Failure Code [CA3558]1312
Failure Code [CA3559]1314
Failure Code [CA3562]1316
Failure Code [CA3563]1318
Failure Code [CA3567]1321
Failure Code [CA3568]1324
Failure Code [CA3571]1328
Failure Code [CA3572]1330
Failure Code [CA3574]1332
Failure Code [CA3575]1335
Failure Code [CA3577]1337
Failure Code [CA3578]1339
Failure Code [CA3582]1341
Failure Code [CA3583]1346
Failure Code [CA3596]1348
Failure Code [CA3649]1351
Failure Code [CA3681]1354
Failure Code [CA3682]1359
Failure Code [CA3713]1365
Failure Code [CA3717]1368
Failure Code [CA3718]1369
Failure Code [CA3725]1370
Failure Code [CA3748]1373
Failure Code [CA3751]1375
Failure Code [CA3755]1377
Failure Code [CA3866]1379
Failure Code [CA3867]1383
Failure Code [CA3868]1386
Failure Code [CA3899]1390
Failure Code [CA3911]1393
Failure Code [CA3912]1397
Failure Code [CA3932]1399
Failure Code [CA3933]1401
Failure Code [CA3934]1403
Failure Code [CA3935]1406
Failure Code [CA3936]1408
Failure Code [CA4151]1410
Failure Code [CA4152]1414
Failure Code [CA4155]1418
Failure Code [CA4156]1420
Failure Code [CA4157]1423
Failure Code [CA4158]1425
Failure Code [CA4159]1427
Failure Code [CA4161]1429
Failure Code [CA4162]1432
Failure Code [CA4163]1435
Failure Code [CA4164]1437
Failure Code [CA4165]1440
Failure Code [CA4166]1443
Failure Code [CA4168]1446
Failure Code [CA4169]1451
Failure Code [CA4171]1456
Failure Code [CA4249]1461
Failure Code [CA4251]1465
Failure Code [CA4259]1469
Failure Code [CA4261]1472
Failure Code [CA4277]1475
Failure Code [CA4281]1478
Failure Code [CA4459]1481
Failure Code [CA4461]1483
Failure Code [CA4658]1486
Failure Code [CA4731]1490
Failure Code [CA4732]1491
Failure Code [CA4739]1492
Failure Code [CA4768]1493
Failure Code [CA4769]1495
Failure Code [CA4842]1497
Failure Code [CA4952]1501
Failure Code [CA5115]1503
Failure Code [CA5179]1506
Failure Code [CA5181]1508
Failure Code [CA5383]1510
Failure Code [D110KB]1512
Failure Code [D163KB]1514
Failure Code [D195KA]1516
Failure Code [D195KB]1518
Failure Code [D19JKZ]1520
Failure Code [D811MC] (Machine with KOMTRAX Terminal)1522
Failure Code [D811MC] (Machine with Gateway Function Controller)1523
Failure Code [D862KA] (Machine with KOMTRAX Terminal)1524
Failure Code [D862KA] (Machine with Gateway Function Controller)1525
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1527
Failure Code [D8ALKA] (Machine with Gateway Function Controller)1529
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1532
Failure Code [D8ALKB] (Machine with Gateway Function Controller)1534
Failure Code [D8AQKR]1536
Failure Code [D8G1KT] (Machine with Gateway Function Controller)1540
Failure Code [D8G6KT] (Machine with Gateway Function Controller)1541
Failure Code [DA20MC]1542
Failure Code [DA22KK]1543
Failure Code [DA25KP]1545
Failure Code [DA26KP]1547
Failure Code [DA29KQ]1550
Failure Code [DA2LKA]1552
Failure Code [DA2LKB]1554
Failure Code [DA2QKR]1556
Failure Code [DA2RKR]1561
Failure Code [DAF0KM]1566
Failure Code [DAF0MB]1567
Failure Code [DAF0MC]1568
Failure Code [DAF8KB]1569
Failure Code [DAF9KQ]1570
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)1571
Failure Code [DAFGMC] (Machine with Gateway Function Controller)1572
Failure Code [DAFLKA]1573
Failure Code [DAFLKB]1575
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)1577
Failure Code [DAFQKR] (Machine with Gateway Function Controller)1581
Failure Code [DAZ9KQ]1585
Failure Code [DAZQKR]1586
Failure Code [DB2QKR]1590
Failure Code [DB2RKR]1595
Failure Code [DBP0KM]1600
Failure Code [DBP0KT]1601
Failure Code [DBP5KB]1602
Failure Code [DBP5KY]1605
Failure Code [DBPQKR]1608
Failure Code [DDNRKA]1613
Failure Code [DDNRKY]1615
Failure Code [DDNS00]1617
Failure Code [DGE5KB]1619
Failure Code [DGH2KA]1620
Failure Code [DGH2KB]1622
Failure Code [DHA4KA]1624
Failure Code [DHAAMA]1626
Failure Code [DHACMA]1628
Failure Code [DHPAMA]1630
Failure Code [DHPBMA]1632
Failure Code [DHS3MA]1634
Failure Code [DHS4MA]1637
Failure Code [DHS8MA]1640
Failure Code [DHS9MA]1643
Failure Code [DHSAMA]1646
Failure Code [DHSBMA]1649
Failure Code [DHSCMA]1652
Failure Code [DHSDMA]1655
Failure Code [DHSFMA]1658
Failure Code [DHSGMA]1661
Failure Code [DHSHMA]1664
Failure Code [DHSJMA]1667
Failure Code [DHSVMA]1670
Failure Code [DKULKA]1672
Failure Code [DKULKB]1674
Failure Code [DKULKY]1676
Failure Code [DLM3KA]1678
Failure Code [DLM3KB]1680
Failure Code [DLM3MB]1682
Failure Code [DR10KA]1683
Failure Code [DR12KA]1686
Failure Code [DR20KA]1688
Failure Code [DR21KX]1690
Failure Code [DR30KA]1692
Failure Code [DR31KX]1694
Failure Code [DR40KA]1696
Failure Code [DUMBKA]1698
Failure Code [DUMBKB]1700
Failure Code [DV20KB]1702
Failure Code [DW43KA]1703
Failure Code [DW43KB]1705
Failure Code [DW43KY]1707
Failure Code [DW45KA]1708
Failure Code [DW45KB]1711
Failure Code [DW45KY]1714
Failure Code [DW48KA]1716
Failure Code [DW48KB]1718
Failure Code [DW48KY]1720
Failure Code [DW4CKY]1721
Failure Code [DW4XKA]1723
Failure Code [DW4XKB]1725
Failure Code [DW4XKY]1727
Failure Code [DW7BKA]1728
Failure Code [DW7BKB]1730
Failure Code [DW7BKY]1732
Failure Code [DWK0KA]1733
Failure Code [DWK0KB]1735
Failure Code [DWK0KY]1737
Failure Code [DWK2KA]1738
Failure Code [DWK2KB]1740
Failure Code [DWK8KA]1742
Failure Code [DWK8KB]1744
Failure Code [DWK8KY]1746
Failure Code [DX16KA]1747
Failure Code [DX16KB]1749
Failure Code [DXA2KA]1750
Failure Code [DXA2KB]1753
Failure Code [DXA3KA]1755
Failure Code [DXA3KB]1758
Failure Code [DY20KA]1760
Failure Code [DY20MA]1762
Failure Code [DY2CKB]1764
Failure Code [DY2DKB]1766
Failure Code [DY2EKB]1768
Failure Code [DY2FMA]1770
Failure Code [DY2GKM]1772
Failure Code [F311KA]1774
Failure Code [F311KB]1776
Failure Code [F312KA]1778
Failure Code [F312KB]1780
Failure Code [F313KA]1782
Failure Code [F313KB]1784
Failure Code [F314KA]1787
Failure Code [F314KB]1789
Failure Code [F315KB]1791
Failure Code [F315KY]1793
Failure Code [F316KB]1795
Failure Code [F316KY]1797
Failure Code [F318KB]1799
Failure Code [F318KY]1802
Failure Code [F31AKB]1804
Failure Code [F31AKY]1806
Failure Code [F31BKB]1808
Failure Code [F31BKY]1810
Failure Code [F31CKB]1812
Failure Code [F31CKY]1814
Failure Code [F31DKB]1816
Failure Code [F31DKY]1818
Failure Code [F31EKB]1820
Failure Code [F31EKY]1822
Troubleshooting of Electrical System (E-Mode)1824
E-1 Engine Does Not Start (Engine Does Not Crank)1824
E-2 Manual Preheating System Does Not Operate1830
E-3 Automatic Preheating System Does Not Operate1833
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1835
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1837
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1840
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1841
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1842
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1843
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1844
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1845
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1846
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1847
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1848
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation1849
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum1850
E-17 Display of Fuel Gauge is Different from Actual Fuel Level1852
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1853
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1854
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1855
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1857
E-22 Some Areas of Machine Monitor Screen are Not Shown1858
E-23 Function Switch Does Not Operate1859
E-24 Automatic Warm-up System Does Not Work (in Cold Weather)1860
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1861
E-26 Auto-Decelerator is Not Operated or Canceled with Lever1862
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1863
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1864
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1865
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1866
E-31 Alarm Buzzer Cannot be Canceled1867
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position1868
E-33 Service Mode Cannot be Selected1869
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1870
E-35 All Work Equipment, Swing and Travel Do Not Lock1873
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1875
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1878
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor1880
E-39 One-Touch Power Maximizing Function is Not Cancelled1882
E-40 Alarm Does Not Sound During Travel1883
E-41 Alarm Does Not Stop When Machine Stops1885
E-42 Horn Does Not Sound1886
E-43 Horn Does Not Stop1889
E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1891
E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1892
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated1894
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function1895
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function1896
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function1897
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function1898
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1899
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function1900
E-53 “Swing” is Not Shown Correctly with Monitoring Function1901
E-54 “Travel” is Not Shown Correctly with Monitoring Function1902
E-55 Service is Not Shown Correctly with Monitoring Function1903
E-56 KOMTRAX System Does Not Operate Correctly1905
E-57 Machine Push-Up Function is Not Canceled1906
E-58 Machine Push-up Function Does Not Operate1908
E-59 Step Light Does Not Come On1909
E-60 Step Light Does Not Go Out1911
E-61 Boom Shockless Function Cannot be Canceled1913
E-62 Boom Shockless Function Does Not Work1915
E-63 Electric Grease Gun Does Not Work1916
E-64 Electric Grease Gun Does Not Stop1918
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1919
H-1 All Work Equipment, Swing and Travel Do Not Work1919
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1920
H-3 Unusual Noise is Heard from Around Hydraulic Pump1922
H-4 Engine Speed Drops Largely or Engine Stops1923
H-5 Travel Speed or Power is Low1924
H-6 Auto-Deceleration Function Cannot be Canceled1925
H-7 Speed or Power of Boom is Low1926
H-8 Arm Speed or Power is Low1928
H-9 Bucket Speed or Power is Low1929
H-10 Work Equipment Does Not Move in Single Operation1930
H-11 Hydraulic Drift of Boom is Large1931
H-12 Hydraulic Drift of Arm is Large1932
H-13 Hydraulic Drift of Bucket is Large1933
H-14 Time Lag of Work Equipment is Large1934
H-15 One-Touch Power Maximizing Function Does Not Operate1935
H-16 Machine Push-Up Function Does Not Operate1936
H-17 Machine Does Not Travel Straight1937
H-18 Speed of Boom and Bucket is Slow at Mixed Operation of Arm, Boom and Bucket1938
H-19 Speed of Boom, Arm, Swing and Travel is Slow at Mixed Operation of Bucket, Boom and Arm1939
H-20 Swing Speed is Slow at Mixed Operation of Arm and Swing1940
H-21 Travel Deviation is Large at Start of Traveling1941
H-22 Travel Deviation is Large at Mixed Operation1943
H-23 One of Tracks Does Not Run1944
H-24 Travel Speed Does Not Change1946
H-25 Upper Structure Does Not Swing to Right and Left1947
H-26 Upper Structure Swings Only to Right or Left1948
H-27 Swing Acceleration or Swing Speed is Low in Right and Left Directions1949
H-28 Swing Acceleration or Swing Speed is Low in Only One Direction1950
H-29 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1951
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1952
H-31 Shock is Large When Upper Structure Stops Swing Operation1953
H-32 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation1954
H-33 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1955
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1956
H-35 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)1957
H-36 Unusual Noise is Heard from Around Fan1958
Troubleshooting of Engine (S-Mode)1959
Information Shown in Troubleshooting Table (S-Mode)1959
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1960
S-2 Engine Cranks but No Exhaust Smoke Comes Out1961
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1962
S-4 Engine Startability is Unsatisfactory1963
S-5 Engine Does Not Pick Up Smoothly1965
S-6 Engine Stops During Operation1967
S-7 Engine Runs Rough or is Not Stable1969
S-8 Engine Lacks Power1970
S-9 KDPF Becomes Clogged in a Short Time1972
S-10 Engine Oil Consumption is Excessive1974
S-11 Oil Becomes Dirty Quickly1975
S-12 Fuel Consumption is Excessive1976
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1977
S-14 Oil Pressure Drops1978
S-15 Fuel Mixes Into Engine Oil1980
S-16 Water Mixes Into Engine Oil (Milky)1981
S-17 Coolant Temperature Increases Too High (Overheating)1982
S-18 Unusual Noise is Heard1983
S-19 Vibration is Excessive1984
S-20 Air Cannot be Bled from Fuel Circuit1985
S-21 Active Regeneration is Done Frequently1986
S-22 Active Regeneration Continues Long1988
S-23 White Smoke is Exhausted During Active Regeneration1989
S-24 DEF Consumption is Excessive1990
S-25 There is Unusual Smell (Irritating Odor)1992
S-26 Foreign Materials Enter DEF (DEF Increases)1993
50 Disassembly and Assembly1995
Table of Contents1996
Precautions Before Work2002
Related Information on Disassembly and Assembly2003
How to Read This Manual2003
Coating Materials List2005
Special Tool List2010
Sketches of Special Tools2027
Engine and Cooling System2034
Remove and Install Supply Pump Assembly2034
How to Remove Supply Pump Assembly2034
How to Install Supply Pump Assembly2037
Remove and Install Injector Assembly2042
How to Remove Injector Assembly2042
How to Install Injector Assembly2047
Remove and Install Fuel Doser Assembly2056
How to Remove Fuel Doser Assembly2056
How to Install Fuel Doser Assembly2057
Remove and Install Cylinder Head Assembly2059
How to Remove Cylinder Head Assembly2060
How to Install Cylinder Head Assembly2070
Remove and Install EGR Valve Assembly2087
How to Remove EGR Valve Assembly2087
How to Install EGR Valve Assembly2089
Remove and Install EGR Cooler Assembly2091
How to Remove EGR Cooler Assembly2091
How to Install EGR Cooler Assembly2094
Remove and Install Starter Assembly2098
How to Remove Starting Motor Assembly2098
How to Install Starting Motor Assembly2098
Remove and Install Alternator Belt2100
How to Remove Alternator Belt2100
How to Install Alternator Belt2101
Remove and Install Radiator Assembly2103
How to Remove Radiator Assembly2103
How to Install Radiator Assembly2106
Remove and Install Hydraulic Oil Cooler Assembly2110
How to Remove Hydraulic Oil Cooler Assembly2110
How to Install Hydraulic Oil Cooler Assembly2113
Remove and Install Aftercooler Assembly2117
How to Remove Aftercooler Assembly2117
How to Install Aftercooler Assembly2119
Remove and Install Cooling Fan Motor Assembly2122
How to Remove Cooling Fan Motor Assembly2122
How to Install Cooling Fan Motor Assembly2131
Remove and Install Engine, PTO, and Hydraulic Pump Assembly2140
How to Remove Engine PTO and Hydraulic Assembly2140
How to Install Engine PTO and Hydraulic Assembly2151
Remove and Install Engine Front Oil Seal2162
How to Remove Engine Front Oil Seal2162
How to Install Engine Front Oil Seal2163
Remove and Install Engine Rear Oil Seal2166
How to Remove Engine Rear Oil Seal2166
How to Install Engine Rear Oil Seal2168
Remove and Install Engine Hood Assembly2174
How to Remove Engine Hood Assembly2174
How to Install Engine Hood Assembly2179
Remove and Install Fuel Tank Assembly2184
How to Remove Fuel Tank Assembly2184
How to Install Fuel Tank Assembly2187
Remove and Install DEF Tank Assembly2191
How to Remove DEF Tank Assembly2192
How to Install DEF Tank Assembly2198
Remove and Install DEF Tank Sensor Flange Assembly2203
How to Remove DEF Tank Sensor Flange Assembly2203
How to Install DEF Tank Sensor Flange Assembly2204
Remove and Install DEF Tank Sensor2206
How to Remove DEF Tank Sensor2206
How to Install DEF Tank Sensor2207
Remove and Install DEF Tank Strainer2213
How to Remove DEF Tank Strainer2213
How to Install DEF Tank Strainer2213
Remove and Install KDPF Assembly2214
How to Remove KDPF Assembly2214
How to Install KDPF Assembly2218
Disassemble and Assemble KDPF Assembly2227
How to Disassemble KDPF Assembly2228
How to Assemble KDPF Assembly2232
Remove and Install SCR Assembly2237
How to Remove SCR Assembly2237
How to Install SCR Assembly2239
Remove and Install KDPF and SCR Assembly2243
How to Remove KDPF and SCR Assembly2244
How to Install KDPF and SCR Assembly2250
Remove and Install Bellows Pipe Assembly2262
How to Remove Bellows Pipe Assembly2262
How to Install Bellows Pipe Assembly2264
Remove and Install KCCV Assembly2272
How to Remove KCCV Assembly2272
How to Install KCCV Assembly2273
Remove and Install DEF Mixing Tube2276
How to Remove DEF Mixing Tube2276
How to Install DEF Mixing Tube2281
Remove and Install DEF Injector2288
How to Remove DEF Injector2288
How to Install DEF Injector2291
Remove and Install DEF Pump2295
How to Remove DEF Pump2295
How to Install DEF Pump2298
Remove and Install DEF Hose2301
How to Remove DEF Hose2302
How to Install DEF Hose2310
Remove and Install Air Cleaner Assembly2316
How to Remove Air Cleaner Assembly2316
How to Install Air Cleaner Assembly2317
Remove and Install Air Conditioner Compressor Assembly2318
How to Remove Air Conditioner Compressor Assembly2318
How to Install Air Conditioner Compressor Assembly2319
Remove and Install Air Conditioner Condenser Assembly2320
How to Remove Air Conditioner Condenser Assembly2320
How to Install Air Conditioner Condenser Assembly2321
Power Train2322
Disassemble and Assemble PTO Assembly2322
How to Disassemble PTO Assembly2322
How to Assemble PTO Assembly2323
Remove and Install PTO Assembly2326
How to Remove PTO Assembly2326
How to Install PTO Assembly2327
Remove and Install Travel Motor and Final Drive Assembly2330
How to Remove Travel Motor and Final Drive Assembly2330
How to Install Travel Motor and Final Drive Assembly2331
Disassemble and Assemble Final Drive Assembly2332
How to Disassemble Final Drive Assembly2333
How to Assemble Final Drive Assembly2338
Remove and Install Swing Motor and Swing Machinery Assembly2347
How to Remove Swing Motor and Swing Machinery Assembly2347
How to Install Swing Motor and Swing Machinery Assembly2348
Disassemble and Assemble Swing Machinery Assembly2349
How to Disassemble Swing Machinery Assembly2349
How to Assemble Swing Machinery Assembly2353
Remove and Install Swing Circle Assembly2358
How to Remove Swing Circle Assembly2358
How to Install Swing Circle Assembly2359
Undercarriage and Frame2360
Disassemble and Assemble Recoil Spring Assembly2360
How to Disassemble Recoil Spring Assembly2360
How to Assemble Recoil Spring Assembly2361
Remove and Install Track Roller Assembly2363
How to Remove Track Roller Assembly2363
How to Install Track Roller Assembly2364
Remove and Install Carrier Roller Assembly2365
How to Remove Carrier Roller Assembly2365
How to Install Carrier Roller Assembly2365
Disassemble and Assemble One Track Link Assembly in Field2367
How to Disassemble One Track Link Assembly in Field2369
How to Assemble One Track Link Assembly in Field2370
Separate and Connect Track Assembly2373
How to Separate Track Assembly2373
How to Install Track Assembly2374
Remove and Install Idler and Idler Cushion Assembly2376
How to Remove Idler and Idler Cushion Assembly2376
How to Install Idler and Idler Cushion Assembly2377
Disassemble and Assemble Idler Assembly2378
How to Disassemble Idler Assembly2378
How to Assemble Idler Assembly2379
Disassemble and Assemble Idler Cushion Assembly2382
How to Disassemble Idler Cushion Assembly2382
How to Assemble Idler Cushion Assembly2383
Disassemble and Assemble Track Roller Assembly2385
How to Disassemble Track Roller Assembly2385
How to Assemble Track Roller Assembly2386
Disassemble and Assemble Carrier Roller Assembly2389
How to Disassemble Carrier Roller Assembly2389
How to Assemble Carrier Roller Assembly2390
Remove and Install Revolving Frame Assembly2392
How to Remove Revolving Frame Assembly2392
How to Install Revolving Frame Assembly2393
Remove and Install Counterweight Assembly2395
How to Remove Counterweight Assembly2395
How to Install Counterweight Assembly2395
Hydraulic System2398
Remove and Install Center Swivel Joint Assembly2398
How to Remove Center Swivel Joint Assembly2398
How to Install Center Swivel Joint Assembly2399
Disassemble and Assemble Center Swivel Joint Assembly2400
How to Disassemble Center Swivel Joint Assembly2401
How to Assemble Center Swivel Joint Assembly2402
Remove and Install Hydraulic Tank Assembly2403
How to Remove Hydraulic Tank Assembly2403
How to Install Hydraulic Tank Assembly2405
Remove and Install Hydraulic Pump Assembly2408
How to Remove Hydraulic Pump Assembly2408
How to Install Hydraulic Pump Assembly2410
Remove and Install Control Valve Assembly2416
How to Remove Control Valve Assembly2416
How to Install Control Valve Assembly2419
Remove and Install Swing Motor Assembly2423
How to Remove Swing Motor Assembly2423
How to Install Swing Motor Assembly2424
Disassemble and Assemble Work Equipment PPC Valve Assembly2425
How to Disassemble Work Equipment PPC Valve Assembly2425
How to Assemble Work Equipment PPC Valve Assembly2426
Disassemble and Assemble Travel PPC Valve Assembly2428
How to Disassemble Travel PPC Valve Assembly2428
How to Assemble Travel PPC Valve Assembly2429
Disassemble and Assemble Grease Gun Assembly2431
How to Disassemble Grease Gun Assembly2431
How to Assemble Grease Gun Assembly2431
Work Equipment2432
Remove and Install Bucket Cylinder Assembly2432
How to Remove Bucket Cylinder Assembly2432
How to Install Bucket Cylinder Assembly2433
Remove and Install Arm Cylinder Assembly2435
How to Remove Arm Cylinder Assembly2435
How to Install Arm Cylinder Assembly2436
Remove and Install Boom Cylinder Assembly2438
How to Remove Boom Cylinder Assembly2438
How to Install Boom Cylinder Assembly2439
Remove and Install Bucket Assembly2441
How to Remove Bucket Assembly2441
How to Install Bucket Assembly2442
Remove and Install Arm Assembly2443
How to Remove Arm Assembly2443
How to Install Arm Assembly2445
Remove and Install Boom Assembly2447
How to Remove Boom Assembly2447
How to Install Boom Assembly2448
Remove and Install Work Equipment Assembly2450
How to Remove Work Equipment Assembly2450
How to Install Work Equipment Assembly2452
Disassemble and Assemble Anti-Drop Valve Assembly2454
How to Disassemble Anti-Drop Valve Assembly2454
How to Assemble Anti-Drop Valve Assembly2454
Disassemble and Assemble Work Equipment Cylinder Assembly2455
How to Disassemble Work Equipment Cylinder Assembly2456
How to Assemble Work Equipment Cylinder Assembly2458
CAB Related Parts2463
Remove and Install Operator Cab Assembly2463
How to Remove Operator Cab Assembly2463
How to Install Operator Cab Assembly2470
Remove and Install Operator Cab Glass (Adhered Glass)2479
How to Remove Operator Cab Glass (Adhered Glass)2481
How to Install Operator Cab Glass (Adhered Glass)2481
Remove and Install Front Window Assembly2491
How to Remove Front Window Assembly2491
How to Install Front Window Assembly2494
Remove and Install Floor Frame Assembly2500
How to Remove Floor Frame Assembly2500
How to Install Floor Frame Assembly2503
Remove and Install Air Conditioner Unit Assembly2508
How to Remove Air Conditioner Unit Assembly2508
How to Install Air Conditioner Unit Assembly2513
Remove and Install Operator Seat2520
How to Remove Operator Seat2520
How to Install Operator Seat2522
How to Remove and Install Seat Belt2525
How to Remove Seat Belt2525
How to Install Seatbelt2525
Remove and Install Work Equipment Control Lever Assembly2527
How to Remove Work Equipment Control Lever Assembly2527
How to Install Work Equipment Control Lever Assembly2533
Remove and Install Front Wiper Assembly2541
How to Remove Front Wiper Assembly2541
How to Install Front Wiper Assembly2546
Electrical System2555
Remove and Install Engine Controller Assembly2555
How to Remove Engine Controller Assembly2555
How to Install Engine Controller Assembly2556
Remove and Install Pump Controller Assembly2559
How to Remove Pump Controller Assembly2559
How to Install Pump Controller Assembly2561
Remove and Install KomVision Controller Assembly2564
How to Remove KomVision Controller Assembly2564
How to Install KomVision Controller Assembly2565
Remove and Install Machine Monitor Assembly2566
How to Remove Machine Monitor Assembly2566
How to Install Machine Monitor Assembly2568
Remove and Install Mass Air Flow and Temperature Sensor2572
How to Remove Mass Air Flow and Temperature Sensor2572
How to Install Mass Air Flow and Temperature Sensor2573
Remove and Install KCCV Crankcase Pressure Sensor2574
How to Remove KCCV Crankcase Pressure Sensor2574
How to Install KCCV Crankcase Pressure Sensor2575
Remove and Install SCR Temperature Sensor2577
How to Remove SCR Temperature Sensor2577
How to Install SCR Temperature Sensor2579
Remove and Install KomVision Camera2581
How to Remove KomVision Camera2581
How to Install KomVision Camera2582
Remove and Install KOMTRAX Terminal Assembly2584
How to Remove KOMTRAX Terminal Assembly2584
How to Install KOMTRAX Terminal Assembly2586
Remove and Install Gateway Function Controller Assembly2588
How to Remove Gateway Function Controller Assembly2588
How to Install Gateway Function Controller Assembly2593
Remove and Install Communication Terminal Wiring Harness2598
How to Remove Communication Terminal Wiring Harness2598
How to Install Communication Terminal Wiring Harness2606
Remove and Install Communication Terminal2615
How to Remove Communication Terminal2615
How to Install Communication Terminal2617
60 Maintenance Standard2619
Table of Contents2620
Engine and Cooling System2621
Maintenance Standard for Engine Mount2621
Maintenance Standard for PTO2623
Maintenance Standard for Cooling System2624
Maintenance Standard for Cooling Fan Pump2625
Maintenance Standard for Servo Valve2626
Maintenance Standard for Cooling Fan Motor2627
Power Train2628
Maintenance Standard for Swing Circle2628
Maintenance Standard for Swing Machinery2629
Maintenance Standard for Final Drive2631
Maintenance Standard for Sprocket2633
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2634
Undercarriage and Frame2635
Maintenance Standard for Track Frame and Idler Cushion2635
Maintenance Standard for Idler2637
Maintenance Standard for Track Roller2639
Maintenance Standard for Carrier Roller2640
Maintenance Standard for Track Shoes2641
Maintenance Standard for Double Shoes2644
Maintenance Standard for Triple Shoes2645
Hydraulic System2646
Maintenance Standard for Main Pump2646
Maintenance Standard for Main Pump Servo Valve2648
Maintenance Standard for Main Pump TVC Valve2650
Maintenance Standard for Main Pump CO and NC Valve2651
Maintenance Standard for Swing Motor2652
Maintenance Standard for Travel Motor2653
Maintenance Standard for Control Valve2655
Maintenance Standard for Travel Shuttle Valve of Control Valve2662
Maintenance Standard for Variable Back Pressure Valve2663
Maintenance Standard for Work Equipment and Swing PPC Valve2664
Maintenance Standard for Travel PPC Valve2667
Maintenance Standard for 1st-Line Attachment PPC Valve2670
Maintenance Standard for Solenoid Valve2672
Maintenance Standard for Center Swivel Joint2673
Work Equipment2674
Maintenance Standard for Work Equipment Linkage2674
Dimensions of Arm2679
Dimensions of Bucket2681
Maintenance Standard for Boom Cylinder2683
Maintenance Standard for Arm Cylinder2684
Maintenance Standard for Bucket Cylinder2685
80 Appendix2687
Table of Contents2688
Precautions Before Work2690
Air Conditioner System2691
Precautions for Refrigerant2691
Air Conditioner Component2692
Specifications of Air Conditioner2694
Structure and Function of Refrigeration Cycle2695
Outline of Refrigeration Cycle2696
Component Parts of Air Conditioner System2698
Air Conditioner Unit2698
Configuration Diagram of Air Conditioner Unit2698
Function of Air Conditioner Unit2700
Component Parts of Air Conditioner Unit2702
Function of Evaporator as Air Conditioner Unit Component2703
Function of Heater Core as Air Conditioner Unit Component2703
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2703
Function of Servo Motor as Air Conditioner Unit Component2703
Structure of Expansion Valve as Air Conditioner Unit Component2704
Function of Expansion Valve as Air Conditioner Unit Component2704
Operate Expansion Valve as Air Conditioner Unit Component2704
Function of Dual Pressure Switch2705
Air Conditioner Controller2706
Structure of Air Conditioner Controller2706
Compressor2707
Structure of Compressor2707
Specifications of Compressor2707
Function of Compressor2707
Condenser2708
Structure of Condenser2708
Specifications of Condenser2708
Function of Condenser2708
Receiver Drier2709
Structure of Receiver Dryer2709
Specifications of Receiver Dryer2709
Function of Receiver Dryer2709
Air Conditioner Related Sensors2710
Structure of Sunlight Sensor2710
Function of Sunlight Sensor2710
Structure of Outside Temperature Sensor2710
Function of Outside Air Temperature Sensor2710
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2712
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2714
System Diagram of Air Conditioner2716
Input and Output Signals of Air Conditioner Controller2717
Function of Air Conditioner Controller2718
Locations of Air Conditioner Parts and Layout of Connectors2719
Examine Air Leakage (Duct)2723
How to Examine Air Leakage (Duct)2723
Examine Air Conditioner with Self-Diagnosis Function2725
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2726
Examine Vent (Mode) Changeover2727
How to Examine Vent (Mode) Changeover2727
Examine Fresh/Recirc Air Changeover2729
How to Examine Fresh/Recirc Air Changeover2729
Examine Sunlight Sensor2730
How to Examine Sunlight Sensor2730
Examine Refrigerant (Dual) Pressure Switch2731
How to Examine Refrigerant (Dual) Pressure Switch2731
Examine Relay2732
How to Examine Relay2732
Air Conditioner Troubleshooting Chart 12733
Air Conditioner Troubleshooting Chart 22734
Information Shown in Troubleshooting Table2737
Failure Code [879AKA]2738
Failure Code [879AKB]2739
Failure Code [879BKA]2740
Failure Code [879BKB]2742
Failure Code [879CKA]2744
Failure Code [879CKB]2745
Failure Code [879DKZ]2746
Failure Code [879EMC]2748
Failure Code [879FMC]2749
Failure Code [879GKX]2750
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2752
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2754
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2757
Troubleshooting for Fresh/Recirc Air Changeover2759
Troubleshooting by Gauge Pressure2761
Connect Service Tool2764
How to Connect Service Tool2764
Precautions for Disconnection and Connection of Air Conditioner Piping2766
Handle Compressor Oil2768
How to Replace Desiccant2770
90 Circuit Diagrams2773
Table of Contents2774
Hydraulic Circuit Diagram2775
Symbols Used in Hydraulic Circuit Diagram2775
Hydraulic Circuit Diagram (1/3)2779
Hydraulic Circuit Diagram (2/3)2781
Hydraulic Circuit Diagram (3/3)2783
Electrical Circuit Diagram2785
Symbols Used in Electric Circuit Diagram2785
Electrical Circuit Diagram (1/10) (Machine with KOMTRAX Terminal)2789
Electrical Circuit Diagram (2/10) (Machine with KOMTRAX Terminal)2791
Electrical Circuit Diagram (3/10) (Machine with KOMTRAX Terminal)2793
Electrical Circuit Diagram (4/10) (Machine with KOMTRAX Terminal)2795
Electrical Circuit Diagram (5/10) (Machine with KOMTRAX Terminal)2797
Electrical Circuit Diagram (6/10) (Machine with KOMTRAX Terminal)2799
Electrical Circuit Diagram (7/10) (Machine with KOMTRAX Terminal)2801
Electrical Circuit Diagram (8/10) (Machine with KOMTRAX Terminal)2803
Electrical Circuit Diagram (9/10) (Machine with KOMTRAX Terminal)2805
Electrical Circuit Diagram (10/10) (Machine with KOMTRAX Terminal)2807
Electrical Circuit Diagram (1/11) (Machine with Gateway Function Controller)2809
Electrical Circuit Diagram (2/11) (Machine with Gateway Function Controller)2811
Electrical Circuit Diagram (3/11) (Machine with Gateway Function Controller)2813
Electrical Circuit Diagram (4/11) (Machine with Gateway Function Controller)2815
Electrical Circuit Diagram (5/11) (Machine with Gateway Function Controller)2817
Electrical Circuit Diagram (6/11) (Machine with Gateway Function Controller)2819
Electrical Circuit Diagram (7/11) (Machine with Gateway Function Controller)2821
Electrical Circuit Diagram (8/11) (Machine with Gateway Function Controller)2823
Electrical Circuit Diagram (9/11) (Machine with Gateway Function Controller)2825
Electrical Circuit Diagram (10/11) (Machine with Gateway Function Controller)2827
Electrical Circuit Diagram (11/11) (Machine with Gateway Function Controller)2829
Index2831

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24