Komatsu PC170LC-11 Excavator Shop Manual SEN06769-06 PDF

Description

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06769-06 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06769-06 – PDF DOWNLOAD 

Language : English
Pages : 2662
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06769-06 – PDF DOWNLOAD 

SERIAL NUMBERS 35497 and up

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.

TABLE OF CONTENTS:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06769-06 – PDF DOWNLOAD 

SERIAL NUMBERS 35497 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: PC170LC-11 93
Working Range Drawings 95
Working Range Drawings: PC170LC-11 95
Specifications 96
Specification: PC170LC-11 96
Weight Table 99
Weight Table: PC170LC-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 112
Function of Urea SCR System 113
Function of DEF System 113
Inducement Strategy 115
Component Parts of Urea SCR System 123
DEF Mixing Tube 123
SCR Assembly 123
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 132
System Operating Lamp System 134
System Diagram of System Operating Lamp System 134
Function of Operation Lamp System 134
Battery Isolator 136
Function of Battery Isolator 136
Engine System 137
Layout Drawing of Engine System 137
Specifications of Engine System 138
Function of Engine System 138
Engine Control System 139
System Diagram of Engine Control 139
Function of Engine Control System 140
Auto-Deceleration System 143
System Diagram of Auto-Deceleration System 143
Function of Auto-Deceleration System 143
Operation of Auto-Deceleration System 144
Engine Automatic Warm-up System 145
System Diagram of Engine Automatic Warm-up System 145
Function of Engine Automatic Warm-up System 145
Overheat Prevention System 147
Overheat Prevention System Diagram 147
Function of Overheat Prevention System 147
Turbocharger Protection System 149
System Diagram of Turbocharger Protection System 149
Function of Turbocharger Protection System 149
Automatic Idle Stop System 151
System Diagram of Automatic Idle Stop System 151
Function of Automatic Idle Stop System 151
Component Parts of Engine System 154
VGT 154
EGR System 156
EGR Valve 158
EGR Cooler 160
KCCV System 161
KCCV Ventilator 163
KDOC 165
Cooling System 169
Layout Drawing of Cooling System 169
Specifications of Cooling System 170
Fan Speed Control System of Fan Clutch 171
Fan Speed Control System Diagram of Fan Clutch 171
Function of Fan Speed Control System of Fan Clutch 172
Engine Output Control System of Fan Clutch 173
Engine Output Control System Diagram of Fan Clutch 173
Function of Engine Output Control System of Fan Clutch 173
Component Parts of Cooling System 175
Fan Clutch 175
Control System 176
Layout Drawing of Control System 176
Machine Monitor System 179
System Diagram of Machine Monitor System 179
Function of Machine Monitor System 179
KomVision System 181
Layout Drawing of KomVision System 181
System Diagram of KomVision System 183
Function of KomVision System 183
KOMTRAX System 185
System Diagram of KOMTRAX System 185
Function of KOMTRAX System 185
PPC Levers 186
LH PPC Lever 186
RH PPC Lever 187
Automatic Grease System 188
Outline of AUTO Grease System 188
Component Parts of Control System 200
Machine Monitor 200
KomVision Controller 213
KomVision Camera 217
KOMTRAX Terminal 217
Pump Controller 220
Resistor for PC-EPC Valve 224
CAN Terminating Resistor 224
PPC Oil Pressure Switch 225
Engine Controller 226
Fuel Control Dial 232
Hydraulic System 235
Layout Drawing of Hydraulic System 235
CLSS 239
Structure of CLSS 239
Function of CLSS 240
Engine and Pump Combined Control System 242
Engine and Pump Combined Control System Diagram 242
Function of Engine and Pump Combined Control System 243
Pump and Valve Control System 248
Pump and Valve Control System Diagram 248
Function of Pump and Valve Control System 249
Component Parts of Hydraulic System 251
Hydraulic Tank 251
Main Pump 253
Pilot Oil Filter 276
Control Valve 276
Work Equipment System 341
Layout Drawing of Work Equipment System 341
One-Touch Power Maximizing System 345
System Diagram of One-Touch Power Maximizing System 345
Function of One-Touch Power Maximizing System 345
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
Attachment Oil Flow Adjuster System 350
Attachment Oil Flow Adjuster System Diagram 350
Function of Attachment Oil Flow Adjuster System 351
Component Parts of Work Equipment System 352
Work Equipment and Swing PPC Valve 352
1st-Line Attachment PPC Valve (with EPC Valve) 358
2nd-Line Attachment PPC Valve 364
Solenoid Valve 367
Boom Anti-drop Valve 369
Arm Anti-Drop Valve 373
Attachment Circuit Selector Valve (For High Pressure) 377
Attachment Circuit Selector Valve (For Low Pressure) 379
Pilot Circuit Accumulator 382
Attachment Circuit Accumulator 383
Swing System 384
Layout Drawing of Swing System 384
Swing Control System Diagram 388
Function of Swing Control System 388
Component Parts of Swing System 391
Swing Motor 391
Swing Machinery 394
Swing Circle 396
Travel System 398
Layout Drawing of Travel System 398
System Diagram of Travel Control System 401
Function of Travel Control System 401
Component Parts of Travel System 403
Travel Motor 403
Final Drive 415
Travel PPC Valve 416
Center Swivel Joint 421
Undercarriage and Frame 423
Layout Drawing of Undercarriage 423
Specifications of Undercarriage 424
Work Equipment 425
Structure of Work Equipment 425
Function of Work Equipment 426
Work Equipment Clearance Adjustment Shim 427
Function of Work Equipment Clearance Adjustment Shim 427
Bucket Clearance Adjustment Shim 428
Function of Bucket Clearance Adjustment Shim 428
CAB Related Parts 429
ROPS CAB 429
Structure of ROPS CAB 429
Function of ROPS CAB 429
CAB Mount 430
Structure of CAB Mount 430
Function of CAB Mount 430
CAB Tipping Stopper 431
Structure of CAB Tipping Stopper 431
Function of CAB Tipping Stopper 431
20 Standard Value Table 433
Table of Contents 434
Standard Value Table for Engine 435
Standard Value Table for Engine: PC170LC-11 435
Standard Value Table for Machine 439
Standard Value Table for Machine: PC170LC-11 439
Machine Posture and Procedures to Measure Performance 452
30 Testing and Adjusting 457
Table of Contents 458
Precautions Before Work 461
Related Information on Testing and Adjusting 462
Tools for Testing and Adjusting 462
Sketch of Tools for Testing and Adjusting 469
Engine and Cooling System 471
Examine Engine Speed 471
How to Examine Engine Speed 471
Examine Boost Pressure 473
How to Examine Boost Pressure on Machine Monitor 473
How to Examine Boost Pressure by Testing Tool 474
Examine Exhaust Gas Color 475
How to Examine Exhaust Gas Color with the Handy Smoke Checker 475
How to Examine Exhaust Gas Color with Smoke Meter 476
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 485
How to Examine Blowby Pressure 485
Examine Engine Oil Pressure 487
How to Examine Engine Oil Pressure 487
Examine Fuel Pressure 488
How to Examine Fuel Pressure 489
Examine Fuel Discharge, Return and Leakage 493
How to Examine Fuel Discharge, Return, and Leakage 494
Bleed Air from Fuel System 498
How to Bleed Air from Fuel System 498
Examine Fuel Circuit for Leakage 499
How to Examine Fuel System for Leakage 499
Handle Cylinder Cut-out Mode Operation 501
Handle No-Injection Cranking Operation 502
Examine and Adjust Air Conditioner Compressor Belt Tension 503
How to Examine Air Conditioner Compressor Belt 503
How to Adjust Air Conditioner Compressor Belt 503
How to Replace Fan Belt 505
Examine Fan Belt and Alternator Belt 506
How to Examine Fan Belt and Alternator Belt 506
Examine Automatic Tensioner 507
How to Examine Automatic Tensioner 507
Examine Cooling Fan Speed 508
How to Examine Cooling Fan Speed 508
Examine SCR Related Functions 509
Examine DEF Pump Raised Pressure 512
Examine Injection Volume from DEF Injector 514
Examine DEF Line Heater Relay 1 518
Examine DEF Line Heater Relay 2 521
Examine DEF Pump Heater Relay 523
Examine DEF Tank Heater Valve 527
Examine SCR Denitration Efficiency 529
Clean DEF Tank 533
How to Clean DEF Tank 533
Clean DEF Pump 537
How to Clean DEF Pump 537
Bleed Air from Coolant Circuit of DEF Tank 544
How to Bleed Air from Coolant Circuit of DEF Tank 544
Power Train 546
Examine Swing Circle Bearing Clearance 546
How to Examine Swing Circle Bearing Clearance 546
Undercarriage and Frame 547
Examine and Adjust Track Tension 547
How to Examine Track Tension 547
How to Adjust Track Tension 547
Hydraulic System 549
Release Remained Pressure in Hydraulic Circuit 549
How to Release Remained Pressure from Hydraulic Tank 549
How to Release Remained Pressure in Hydraulic Cylinder Circuit 549
How to Release Remained Pressure from Swing Motor Circuit 551
How to Release Remained Pressure from Travel Motor Circuit 551
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 552
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 552
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 558
Examine Oil Pressure of Control Circuit 560
How to Examine Oil Pressure in Control Circuit 560
Examine and adjust oil pressure in pump PC control circuit 562
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 562
How to Examine PC-EPC Valve Outlet Pressure 563
How to Adjust Oil Pressure in Pump PC Control Circuit 564
Examine and Adjust Oil Pressure in Pump LS Control Circuit 566
How to Examine LS Differential Pressure with Machine Monitor 566
How to Examine LS Differential Pressure by Testing Tool 568
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 570
How to Adjust LS Valve 571
Examine Outlet Pressure of Solenoid Valve 572
How to Examine Outlet Pressure of Solenoid Valve 572
Operating Condition of Solenoid Valve 573
Examine PPC Valve Outlet Pressure 576
How to Examine Outlet Pressure in PPC Valve 576
Adjust Play of Work Equipment and Swing PPC Valves 578
How to Adjust Play of Work Equipment and Swing PPC Valves 578
Measure and Adjust Quick Coupler Control Valve Output Pressure 579
Examine Pump Swash Plate Sensor 581
How to Examine pump swash plate sensor 581
Examine and Adjust Travel Deviation 582
How to Examine Travel Deviation 582
How to Adjust Travel Deviation 582
Examine Parts Which Cause Hydraulic Drift of Work Equipment 585
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 585
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 585
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 586
Examine Oil Leakage 587
How to Examine Oil Leakage from Boom Cylinder 587
How to Examine Oil Leakage from Arm Cylinder 587
How to Examine Oil Leakage from Bucket Cylinder 588
How to Examine Oil Leakage from Swing Motor 589
How to Examine Oil Leakage from Travel Motor 589
Bleed Air from Hydraulic System 590
How to Bleed Air from Hydraulic System 591
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 594
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 594
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 598
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 598
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 602
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 602
CAB Related Parts 609
Examine CAB Tipping Stopper 609
How to Examine Cab Tipping Stopper 609
How to Adjust Mirrors 610
Procedure to Adjust Machine Left Front Mirror (A) 610
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 611
Procedure to Adjust Machine Right Front Mirror (B) 612
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 613
Procedure to Adjust Machine Right Side Mirror (C) 615
Electrical System 616
Set and Operate Machine Monitor 616
Operator Mode 619
Function to Show Operator Identification Input Screen 619
Function to Show Technician Identification Status Screen 620
Examine Function by LCD (Liquid Crystal Display) 620
Examine Function of Service Meter 621
Usage Limitation and Maintenance Password Change Function 621
Service Mode 623
How to Operate Service Mode 623
How to See Pre-defined Monitoring Information 625
How to Examine Self-Define Monitor Information 632
Abnormality Record Menu 642
How to See Maintenance Record 646
Maintenance Mode Setting 647
How to Set Phone Number Entry 651
Default Menu 652
Diagnostic Tests Menu 660
Adjustment Menu 667
No-Injection Cranking Operation 689
KOMTRAX Settings Menu 690
How to Show Service Message 692
How to Start Up KOMTRAX Terminal 694
Adjust Rearview Camera Angle 699
How to Adjust Rearview Camera Angle 699
Adjust KomVision Camera Angle 702
How to Adjust KomVision Camera Angle 703
Adjust KomVision Related Function 707
Setting of KomVision (Main Setting) 707
Setting of KomVision (Camera Setting) 709
Setting of KomVision (Camera Calibration) 709
KomVision screen – Check 12 m visibility 723
Handle Voltage Circuit of Engine Controller 726
Handle Battery Isolator Switch 727
Examine Diodes 728
How to Examine Diodes by Digital Tester 728
How to Examine Diodes by Analog Tester 728
Pm Clinic 729
Pm Clinic Service 729
Pm Clinic Check Sheet: PC170LC-11 733
40 Troubleshooting 743
Table of Contents 744
Precautions Before Work 754
Related Information to Troubleshooting 755
General Troubleshooting Points 755
Troubleshooting Points for Urea SCR System 756
Sequence of Events in Troubleshooting 770
Checks Before Troubleshooting 772
Inspection Procedure Before Troubleshooting 774
Walk-Around Check 774
Test in Accordance with Testing Procedure 776
Examine Fuel Level and Type 776
Examine for Impure Ingredient in Fuel 776
Examine Fuel Prefilter 777
Examine Water Separator, Drain Water and Sediment 777
How to Replace Fuel Prefilter Cartridge 778
Examine Fuel Main Filter 780
Examine Engine Oil Level (Oil Quantity in Oil Pan) 781
Examine Coolant Level (Reservoir Tank) 782
Examine Air Cleaner Clogging 783
Clean Outer Element 783
Replace Element 786
Examine Hydraulic Oil Level 788
Examine Hydraulic Oil Strainer 789
Examine Hydraulic Oil Filter 790
Examine Oil Level in Swing Machinery Case 791
Examine Oil Level in Damper Case 792
Examine Oil Level in Final Drive Case 792
Bleed Air from Fuel System 793
Bleed Air from Hydraulic System 793
How to Examine Electric Equipment 793
Automatic Grease System 799
Find Malfunctions 799
Malfunction Finding Procedures 801
Preparation for Troubleshooting of Electrical System 803
Preparation for Troubleshooting of Machine Monitor 803
Preparation for Troubleshooting of Engine Controller 803
Preparation for Troubleshooting of Pump Controller 803
Preparation for Troubleshooting of KOMTRAX Terminal 804
How to Disconnect and Connect Connector with a Special Lock 804
Procedure for Troubleshooting 808
Symptom and Troubleshooting Numbers 811
Information Shown in Troubleshooting Table 815
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 817
Connector List and Layout 820
Connector Contact Connection Table 833
T-Branch Box and T-Branch Adapter Table 873
Fuse Location Table 879
Precautions When You Replace KDOC 882
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 883
Failure Code Table 885
Troubleshooting by Failure Code (Display of Code) 903
Failure Code [6AZ0ZG] 903
Failure Code [879AKA] 905
Failure Code [879AKB] 906
Failure Code [879BKA] 907
Failure Code [879BKB] 909
Failure Code [879CKA] 911
Failure Code [879CKB] 912
Failure Code [879DKZ] 913
Failure Code [879EMC] 915
Failure Code [879FMC] 916
Failure Code [879GKX] 917
Failure Code [989L00] 919
Failure Code [989M00] 920
Failure Code [989N00] 921
Failure Code [A1U0N3] 922
Failure Code [A1U0N4] 924
Failure Code [A900FR] 926
Failure Code [A900N6] 927
Failure Code [A900NY] 928
Failure Code [AA10NX] 929
Failure Code [AB00KE] 931
Failure Code [AQ10MB] 934
Failure Code [AQ10N3] 936
Failure Code [AS00N3] 938
Failure Code [AS00R2] 940
Failure Code [AS00R3] 941
Failure Code [AS00R4] 942
Failure Code [AS00R5] 943
Failure Code [AS00R6] 944
Failure Code [AS00ZK] 945
Failure Code [AS10KM] 946
Failure Code [AS10NR] 947
Failure Code [AS10NT] 949
Failure Code [B@BAZG] 950
Failure Code [B@BAZK] 951
Failure Code [B@BCNS] 953
Failure Code [B@BCZK] 954
Failure Code [B@HANS] 956
Failure Code [CA115] 957
Failure Code [CA122] 958
Failure Code [CA123] 960
Failure Code [CA131] 962
Failure Code [CA132] 964
Failure Code [CA144] 966
Failure Code [CA145] 968
Failure Code [CA153] 970
Failure Code [CA154] 973
Failure Code [CA187] 976
Failure Code [CA221] 978
Failure Code [CA222] 980
Failure Code [CA227] 982
Failure Code [CA234] 984
Failure Code [CA238] 985
Failure Code [CA239] 986
Failure Code [CA249] 987
Failure Code [CA256] 989
Failure Code [CA271] 991
Failure Code [CA272] 993
Failure Code [CA295] 995
Failure Code [CA322] 996
Failure Code [CA324] 998
Failure Code [CA331] 1000
Failure Code [CA332] 1002
Failure Code [CA343] 1004
Failure Code [CA351] 1005
Failure Code [CA352] 1007
Failure Code [CA356] 1009
Failure Code [CA357] 1011
Failure Code [CA386] 1013
Failure Code [CA428] 1014
Failure Code [CA429] 1016
Failure Code [CA435] 1018
Failure Code [CA441] 1020
Failure Code [CA442] 1022
Failure Code [CA451] 1024
Failure Code [CA452] 1026
Failure Code [CA488] 1028
Failure Code [CA515] 1029
Failure Code [CA516] 1031
Failure Code [CA553] 1033
Failure Code [CA555] 1034
Failure Code [CA556] 1035
Failure Code [CA559] 1036
Failure Code [CA595] 1039
Failure Code [CA687] 1041
Failure Code [CA689] 1043
Failure Code [CA691] 1045
Failure Code [CA692] 1047
Failure Code [CA697] 1049
Failure Code [CA698] 1050
Failure Code [CA731] 1051
Failure Code [CA778] 1053
Failure Code [CA1117] 1058
Failure Code [CA1664] 1060
Failure Code [CA1669] 1062
Failure Code [CA1673] 1063
Failure Code [CA1677] 1064
Failure Code [CA1678] 1065
Failure Code [CA1682] 1066
Failure Code [CA1683] 1068
Failure Code [CA1684] 1070
Failure Code [CA1686] 1072
Failure Code [CA1691] 1073
Failure Code [CA1694] 1075
Failure Code [CA1695] 1077
Failure Code [CA1696] 1078
Failure Code [CA1712] 1080
Failure Code [CA1713] 1083
Failure Code [CA1714] 1085
Failure Code [CA1715] 1086
Failure Code [CA1776] 1087
Failure Code [CA1777] 1089
Failure Code [CA1843] 1092
Failure Code [CA1844] 1094
Failure Code [CA1885] 1096
Failure Code [CA1887] 1098
Failure Code [CA1896] 1100
Failure Code [CA1898] 1101
Failure Code [CA1938] 1103
Failure Code [CA1942] 1105
Failure Code [CA1961] 1106
Failure Code [CA1962] 1107
Failure Code [CA2185] 1108
Failure Code [CA2186] 1109
Failure Code [CA2198] 1111
Failure Code [CA2249] 1113
Failure Code [CA2272] 1114
Failure Code [CA2288] 1116
Failure Code [CA2311] 1117
Failure Code [CA2349] 1118
Failure Code [CA2353] 1120
Failure Code [CA2357] 1122
Failure Code [CA2373] 1123
Failure Code [CA2374] 1125
Failure Code [CA2375] 1127
Failure Code [CA2376] 1129
Failure Code [CA2387] 1132
Failure Code [CA2554] 1133
Failure Code [CA2634] 1135
Failure Code [CA2635] 1137
Failure Code [CA2636] 1138
Failure Code [CA2637] 1140
Failure Code [CA2771] 1142
Failure Code [CA2961] 1146
Failure Code [CA2973] 1147
Failure Code [CA2976] 1148
Failure Code [CA3142] 1150
Failure Code [CA3143] 1151
Failure Code [CA3144] 1152
Failure Code [CA3146] 1154
Failure Code [CA3147] 1155
Failure Code [CA3148] 1156
Failure Code [CA3151] 1158
Failure Code [CA3165] 1163
Failure Code [CA3228] 1165
Failure Code [CA3229] 1168
Failure Code [CA3231] 1170
Failure Code [CA3232] 1172
Failure Code [CA3235] 1176
Failure Code [CA3239] 1178
Failure Code [CA3241] 1181
Failure Code [CA3242] 1184
Failure Code [CA3251] 1187
Failure Code [CA3313] 1189
Failure Code [CA3314] 1190
Failure Code [CA3315] 1191
Failure Code [CA3419] 1193
Failure Code [CA3421] 1195
Failure Code [CA3497] 1197
Failure Code [CA3498] 1198
Failure Code [CA3545] 1199
Failure Code [CA3547] 1201
Failure Code [CA3558] 1202
Failure Code [CA3559] 1204
Failure Code [CA3562] 1206
Failure Code [CA3563] 1208
Failure Code [CA3567] 1211
Failure Code [CA3568] 1214
Failure Code [CA3571] 1218
Failure Code [CA3572] 1220
Failure Code [CA3574] 1222
Failure Code [CA3575] 1224
Failure Code [CA3577] 1226
Failure Code [CA3578] 1228
Failure Code [CA3582] 1230
Failure Code [CA3583] 1236
Failure Code [CA3596] 1238
Failure Code [CA3649] 1241
Failure Code [CA3681] 1243
Failure Code [CA3682] 1247
Failure Code [CA3713] 1251
Failure Code [CA3717] 1254
Failure Code [CA3718] 1255
Failure Code [CA3724] 1256
Failure Code [CA3725] 1257
Failure Code [CA3741] 1260
Failure Code [CA3748] 1261
Failure Code [CA3755] 1264
Failure Code [CA3866] 1266
Failure Code [CA3868] 1269
Failure Code [CA4152] 1272
Failure Code [CA4155] 1276
Failure Code [CA4156] 1278
Failure Code [CA4157] 1281
Failure Code [CA4159] 1283
Failure Code [CA4164] 1284
Failure Code [CA4165] 1286
Failure Code [CA4166] 1288
Failure Code [CA4168] 1289
Failure Code [CA4169] 1292
Failure Code [CA4171] 1294
Failure Code [CA4249] 1297
Failure Code [CA4251] 1299
Failure Code [CA4261] 1301
Failure Code [CA4277] 1304
Failure Code [CA4459] 1308
Failure Code [CA4461] 1310
Failure Code [CA4533] 1313
Failure Code [CA4534] 1314
Failure Code [CA4731] 1315
Failure Code [CA4732] 1316
Failure Code [CA4739] 1317
Failure Code [CA4768] 1318
Failure Code [CA4769] 1320
Failure Code [CA4842] 1322
Failure Code [CA4952] 1325
Failure Code [CA5115] 1327
Failure Code [CA5179] 1330
Failure Code [CA5181] 1332
Failure Code [CA5387] 1334
Failure Code [CA5388] 1336
Failure Code [CA5389] 1339
Failure Code [CA5391] 1341
Failure Code [CA5392] 1345
Failure Code [CA5393] 1347
Failure Code [CA5394] 1349
Failure Code [CA5395] 1351
Failure Code [CA5396] 1354
Failure Code [CA5631] 1355
Failure Code [CA5632] 1357
Failure Code [CA5938] 1358
Failure Code [D110KB] 1360
Failure Code [D19JKZ] 1362
Failure Code [D811MC] 1365
Failure Code [D862KA] 1366
Failure Code [D8ALKA] 1367
Failure Code [D8ALKB] 1369
Failure Code [D8AQKR] 1371
Failure Code [DA20MC] 1375
Failure Code [DA22KK] 1376
Failure Code [DA25KP] 1379
Failure Code [DA29KQ] 1382
Failure Code [DA2LKA] 1384
Failure Code [DA2LKB] 1386
Failure Code [DA2QKR] 1388
Failure Code [DA2RKR] 1393
Failure Code [DAF0KM] 1398
Failure Code [DAF0MB] 1399
Failure Code [DAF0MC] 1400
Failure Code [DAF8KB] 1401
Failure Code [DAF9KQ] 1403
Failure Code [DAFGMC] 1404
Failure Code [DAFLKA] 1405
Failure Code [DAFLKB] 1407
Failure Code [DAFQKR] 1409
Failure Code [DAZ9KQ] 1413
Failure Code [DAZQKR] 1414
Failure Code [DB2QKR] 1418
Failure Code [DB2RKR] 1423
Failure Code [DBP0KM] 1428
Failure Code [DBP0KT] 1429
Failure Code [DBP5KB] 1430
Failure Code [DBP5KY] 1433
Failure Code [DBPQKR] 1436
Failure Code [DDNRKA] 1441
Failure Code [DDNRKY] 1443
Failure Code [DDNS00] 1445
Failure Code [DFB1KZ] 1447
Failure Code [DFB2KZ] 1449
Failure Code [DFB3L8] 1451
Failure Code [DFB4L8] 1453
Failure Code [DFB5KZ] 1455
Failure Code [DFB6KZ] 1457
Failure Code [DGH2KA] 1459
Failure Code [DGH2KB] 1461
Failure Code [DHA4KA] 1463
Failure Code [DHPAMA] 1465
Failure Code [DHPBMA] 1468
Failure Code [DHS3MA] 1471
Failure Code [DHS4MA] 1474
Failure Code [DHS5MA] 1477
Failure Code [DHS8MA] 1480
Failure Code [DHS9MA] 1483
Failure Code [DHSAMA] 1486
Failure Code [DHSBMA] 1489
Failure Code [DHSCMA] 1492
Failure Code [DHSDMA] 1495
Failure Code [DHX1MA] 1498
Failure Code [DKR0MA] 1500
Failure Code [DKULKA] 1503
Failure Code [DKULKB] 1505
Failure Code [DKULKY] 1507
Failure Code [DLM5KA] 1509
Failure Code [DLM5MB] 1512
Failure Code [DR10KA] 1514
Failure Code [DR12KA] 1517
Failure Code [DR20KA] 1519
Failure Code [DR21KX] 1521
Failure Code [DR30KA] 1523
Failure Code [DR31KX] 1525
Failure Code [DR40KA] 1527
Failure Code [DUMBKA] 1529
Failure Code [DUMBKB] 1531
Failure Code [DV20KB] 1533
Failure Code [DW43KA] 1535
Failure Code [DW43KB] 1537
Failure Code [DW43KY] 1539
Failure Code [DW45KA] 1541
Failure Code [DW45KB] 1544
Failure Code [DW45KY] 1547
Failure Code [DW4CKY] 1549
Failure Code [DW91KA] 1551
Failure Code [DW91KB] 1553
Failure Code [DW91KY] 1555
Failure Code [DWA2KA] 1557
Failure Code [DWA2KB] 1559
Failure Code [DWA2KY] 1561
Failure Code [DWJ0KA] 1563
Failure Code [DWJ0KB] 1565
Failure Code [DWJ0KY] 1567
Failure Code [DWK0KA] 1569
Failure Code [DWK0KB] 1571
Failure Code [DWK0KY] 1573
Failure Code [DWK2KA] 1575
Failure Code [DWK2KB] 1577
Failure Code [DWK2KY] 1579
Failure Code [DWN5KA] 1581
Failure Code [DWN5KB] 1584
Failure Code [DWN5KY] 1587
Failure Code [DWNSKA] 1589
Failure Code [DWNSKB] 1591
Failure Code [DWNSKY] 1593
Failure Code [DXA8KA] 1594
Failure Code [DXA8KB] 1596
Failure Code [DXE4KA] 1598
Failure Code [DXE4KB] 1600
Failure Code [DXE4KY] 1602
Failure Code [DXE7KA] 1604
Failure Code [DXE7KB] 1606
Failure Code [DXE7KY] 1608
Failure Code [DXE8KA] 1610
Failure Code [DXE8KB] 1612
Failure Code [DXE8KY] 1614
Failure Code [DXE9KA] 1616
Failure Code [DXE9KB] 1618
Failure Code [DXE9KY] 1620
Failure Code [DXEAKA] 1622
Failure Code [DXEAKB] 1624
Failure Code [DXEAKY] 1626
Failure Code [DY20KA] 1628
Failure Code [DY20MA] 1630
Failure Code [DY2CKB] 1632
Failure Code [DY2DKB] 1635
Failure Code [DY2EKB] 1637
Failure Code [F311KA] 1639
Failure Code [F311KB] 1641
Failure Code [F312KA] 1643
Failure Code [F312KB] 1645
Failure Code [F313KA] 1647
Failure Code [F313KB] 1649
Failure Code [F314KA] 1652
Failure Code [F314KB] 1654
Failure Code [F315KB] 1656
Failure Code [F315KY] 1658
Failure Code [F316KB] 1660
Failure Code [F316KY] 1662
Failure Code [F318KB] 1664
Failure Code [F318KY] 1667
Failure Code [F31AKB] 1669
Failure Code [F31AKY] 1671
Failure Code [F31BKB] 1673
Failure Code [F31BKY] 1675
Failure Code [F31CKB] 1677
Failure Code [F31CKY] 1679
Failure Code [F31DKB] 1681
Failure Code [F31DKY] 1683
Failure Code [F31EKB] 1685
Failure Code [F31EKY] 1687
Troubleshooting of Electrical System (E-Mode) 1689
E-1 Engine Does Not Start (Engine Does Not Crank) 1689
E-2 Manual Preheating System Does Not Operate 1695
E-3 Automatic Preheating System Does Not Operate 1698
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1700
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1702
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1705
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1706
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1707
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1708
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1709
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1710
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1711
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1712
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1713
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1714
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1715
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1716
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1718
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1719
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1720
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1721
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1723
E-23 Some Areas of Machine Monitor Screen are Not Shown 1724
E-24 Function Switch Does Not Operate 1725
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1726
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1727
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1728
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1729
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1730
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1731
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1732
E-32 Alarm Buzzer Cannot be Canceled 1734
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1735
E-34 Service Mode Cannot be Selected 1736
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1737
E-36 All Work Equipment, Swing and Travel Do Not Lock 1740
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1742
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1745
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1747
E-40 One-Touch Power Maximizing Function is Not Cancelled 1750
E-41 Alarm Does Not Sound During Travel 1751
E-42 Alarm Does Not Stop When Machine Stops 1753
E-43 Horn Does Not Sound 1754
E-44 Horn Does Not Stop 1757
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1759
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1760
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1762
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1763
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1764
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1765
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1766
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1767
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1768
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1769
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1770
E-56 Service is Not Shown Correctly with Monitoring Function 1771
E-57 Attachment Hydraulic Circuit Cannot be Changed 1773
E-58 KOMTRAX System Does Not Operate Correctly 1774
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1775
Information Shown in Troubleshooting Table (H-Mode) 1775
Failure Mode and Cause Table 1776
H-1 All Work Equipment, Swing and Travel Do Not Work 1786
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1787
H-3 Fine Control Performance or Response is Unsatisfactory 1789
H-4 Unusual Noise is Heard from Around Hydraulic Pump 1790
H-5 Engine Speed Drops Largely or Engine Stops 1791
H-6 Speed or Power of Boom is Low 1793
H-7 Arm Speed or Power is Low 1796
H-8 Bucket Speed or Power is Low 1800
H-9 Work Equipment Does Not Move in Single Operation 1802
H-10 Hydraulic Drift of Boom is Large 1803
H-11 Hydraulic Drift of Arm is Large 1804
H-12 Hydraulic Drift of Bucket is Large 1806
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1807
H-14 Time Lag of Work Equipment is Large 1808
H-15 One-Touch Power Maximizing Function Does Not Operate 1809
H-16 Attachment Circuit Cannot be Changed 1810
H-17 Oil Flow in Attachment Circuit Cannot be Changed 1811
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1812
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 1813
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1814
H-21 Machine Does Not Travel Straight 1815
H-22 Machine is Not Steered Correctly or Steering Power is Low 1818
H-23 Travel Speed is Low 1820
H-24 One of Tracks Does Not Run 1822
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1823
H-26 Upper Structure Does Not Swing to Right and Left 1824
H-27 Upper Structure Swings Only to Right or Left 1825
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 1826
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 1827
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1828
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1829
H-32 Shock is Large When Upper Structure Stops Swing Operation 1830
H-33 There is Large Unusual Noise When It Stops Swing Operation 1831
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1832
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1833
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1834
H-37 Unusual Noise is Heard from Around Fan 1835
H-38 Quick coupler cylinder will not extend 1836
H-39 Quick coupler cylinder will not retract (but buzzer does not sound) 1838
H-40 Buzzer Does Not Operate (but Quick Coupler Cylinder Does Retract) 1840
H-41 Quick coupler cylinder extends and retracts slowly 1841
Troubleshooting of Engine (S-Mode) 1842
Information Shown in Troubleshooting Table (S-Mode) 1842
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1843
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1844
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1845
S-4 Engine Startability is Unsatisfactory 1847
S-5 Engine Does Not Pick Up Smoothly 1849
S-6 Engine Stops During Operation 1851
S-7 Engine Runs Rough or is Not Stable 1853
S-8 Engine Lacks Power 1854
S-9 Exhaust Smoke is Black 1856
S-10 Engine Oil Consumption is Excessive 1858
S-11 Oil Becomes Dirty Quickly 1859
S-12 Fuel Consumption is Excessive 1860
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1861
S-14 Oil Pressure Drops 1862
S-15 Fuel Mixes Into Engine Oil 1864
S-16 Water Mixes Into Engine Oil (Milky) 1865
S-17 Coolant Temperature Increases Too High (Overheating) 1866
S-18 Unusual Noise is Heard 1867
S-19 Vibration is Excessive 1868
S-20 Air Cannot be Bled from Fuel Circuit 1869
S-21 Active Regeneration is Done Frequently 1870
S-22 Active Regeneration Continues Long 1871
S-23 White Smoke is Exhausted During Active Regeneration 1872
S-24 DEF Consumption is Excessive 1873
S-25 There is Unusual Smell (Irritating Odor) 1875
S-26 Foreign Materials Enter DEF (DEF Increases) 1876
50 Disassembly and Assembly 1877
Table of Contents 1878
Precautions Before Work 1883
Related Information on Disassembly and Assembly 1884
How to Read This Manual 1884
Coating Materials List 1886
Special Tool List 1891
Sketches of Special Tools 1905
Engine and Cooling System 1913
Remove and Install Supply Pump Assembly 1913
How to Remove Supply Pump Assembly 1913
How to Install Supply Pump Assembly 1917
Remove and Install Injector Assembly 1921
How to Remove Injector Assembly 1921
How to Install Injector Assembly 1924
Remove and Install Cylinder Head Assembly 1930
How to Remove Cylinder Head Assembly 1930
How to Install Cylinder Head Assembly 1940
Remove and Install EGR Valve Assembly 1957
How to Remove EGR Valve Assembly 1957
How to Install EGR Valve Assembly 1958
Remove and Install EGR Cooler Assembly 1960
How to Remove EGR Cooler Assembly 1960
How to Install EGR Cooler Assembly 1962
Remove and Install Starter Assembly 1965
How to Remove Starting Motor Assembly 1965
How to Install Starting Motor Assembly 1967
Remove and Install Alternator Belt 1970
How to Remove Alternator Belt 1970
How to Install Alternator Belt 1972
Remove and Install Radiator Assembly 1975
How to Remove Radiator Assembly 1975
How to Install Radiator Assembly 1979
Remove and Install Hydraulic Oil Cooler Assembly 1983
How to Remove Hydraulic Oil Cooler Assembly 1983
How to Install Hydraulic Oil Cooler Assembly 1987
Remove and Install Aftercooler Assembly 1991
How to Remove Aftercooler Assembly 1991
How to Install Aftercooler Assembly 1993
Remove and Install Fan Clutch Assembly 1996
How to Remove Fan Clutch Assembly 1996
How to Install Fan Clutch Assembly 2000
Remove and Install Fan 2004
How to Remove Fan 2004
How to Install Fan 2004
Remove and Install Engine and Main Pump Assembly 2005
How to Remove Engine and Main Pump Assembly 2005
How to Install Engine and Main Pump Assembly 2021
Remove and Install Engine Front Oil Seal 2038
How to Remove Engine Front Oil Seal 2038
How to Install Engine Front Oil Seal 2042
Remove and Install Engine Rear Oil Seal 2048
How to Remove Engine Rear Oil Seal 2048
How to Install Engine Rear Oil Seal 2049
Remove and Install Fuel Cooler Assembly 2052
How to Remove Fuel Cooler Assembly 2052
How to Install Fuel Cooler Assembly 2054
Remove and Install Engine Hood Assembly 2057
How to Remove Engine Hood Assembly 2057
How to Install Engine Hood Assembly 2059
Remove and Install KDOC Assembly 2065
How to Remove KDOC Assembly 2065
How to Install KDOC Assembly 2068
Remove and Install KDOC and SCR Assembly 2071
How to Remove KDOC and SCR Assembly 2071
How to Install KDOC and SCR Assembly 2078
Remove and Install Bellows Pipe Assembly 2085
How to Remove Bellows Pipe Assembly 2085
How to Install Bellows Pipe Assembly 2087
Remove and Install Fuel Tank Assembly 2092
How to Remove Fuel Tank Assembly 2092
How to Install Fuel Tank Assembly 2097
Remove and Install DEF Tank Assembly 2103
How to Remove DEF Tank Assembly 2103
How to Install DEF Tank Assembly 2111
Remove and Install DEF Tank Sensor Flange Assembly 2117
How to Remove DEF Tank Sensor Flange Assembly 2117
How to Install DEF Tank Sensor Flange Assembly 2118
Remove and Install DEF Tank Sensor 2120
How to Remove DEF Tank Sensor 2120
How to Install DEF Tank Sensor 2121
Remove and Install DEF Tank Strainer 2123
How to Remove DEF Tank Strainer 2123
How to Install DEF Tank Strainer 2123
Remove and Install DEF Tank Filler Port Filter 2124
How to Remove DEF Tank Filler Port Filter 2124
How to Install DEF Tank Filler Port Filter 2126
Remove and Install SCR Assembly 2129
How to Remove SCR Assembly 2129
How to Install SCR Assembly 2131
Remove and Install KCCV Assembly 2133
How to Remove KCCV Assembly 2133
How to Install KCCV Assembly 2134
Remove and Install DEF Mixing Tube 2136
How to Remove DEF Mixing Tube 2136
How to Install DEF Mixing Tube 2143
Remove and Install DEF Injector 2149
How to Remove DEF Injector 2149
How to Install DEF Injector 2152
Remove and Install DEF Pump 2155
How to Remove DEF Pump 2155
How to Install DEF Pump 2158
Remove and Install DEF Hose 2161
How to Remove DEF Hose 2161
How to Install DEF Hose 2171
Remove and Install Air Cleaner Assembly 2181
How to Remove Air Cleaner Assembly 2181
How to Install Air Cleaner Assembly 2182
Remove and Install Air Conditioner Compressor Assembly 2185
How to Remove Air Conditioner Compressor Assembly 2185
How to Install Air Conditioner Compressor Assembly 2187
Remove and Install Air Conditioner Condenser Assembly 2190
How to Remove Air Conditioner Condenser Assembly 2190
How to Install Air Conditioner Condenser Assembly 2191
Power Train 2193
Remove and Install Travel Motor and Final Drive Assembly 2193
How to Remove Travel Motor and Final Drive Assembly 2193
How to Install Travel Motor and Final Drive Assembly 2194
Disassemble and Assemble Final Drive Assembly 2195
How to Disassemble Final Drive Assembly 2196
How to Assemble Final Drive Assembly 2199
Remove and Install Swing Motor and Swing Machinery Assembly 2207
How to Remove Swing Motor and Swing Machinery Assembly 2207
How to Install Swing Motor and Swing Machinery Assembly 2209
Disassemble and Assemble Swing Machinery Assembly 2211
How to Disassemble Swing Machinery Assembly 2211
How to Assemble Swing Machinery Assembly 2215
Remove and Install Swing Circle Assembly 2222
How to Remove Swing Circle Assembly 2222
How to Install Swing Circle Assembly 2222
Undercarriage and Frame 2224
Separate and Connect Track Assembly 2224
How to Separate Track Assembly 2224
How to Install Track Assembly 2225
Remove and Install Sprocket 2228
How to Remove Sprocket 2228
How to Install Sprocket 2229
Remove and Install Idler and Idler Cushion Assembly 2230
How to Remove Idler and Idler Cushion Assembly 2230
How to Install Idler and Idler Cushion Assembly 2231
Disassemble and Assemble Idler Assembly 2232
How to Disassemble Idler Assembly 2232
How to Assemble Idler Assembly 2233
Disassemble and Assemble Idler Cushion Assembly 2237
How to Disassemble Idler Cushion Assembly 2237
How to Assemble Idler Cushion Assembly 2238
Disassemble and Assemble Track Roller Assembly 2240
How to Disassemble Track Roller Assembly 2240
How to Assemble Track Roller Assembly 2241
Disassemble and Assemble Carrier Roller Assembly 2244
How to Disassemble Carrier Roller Assembly 2244
How to Assemble Carrier Roller Assembly 2246
Remove and Install Revolving Frame Assembly 2248
How to Remove Revolving Frame Assembly 2248
How to Install Revolving Frame Assembly 2251
Remove and Install Counterweight Assembly 2254
How to Remove Counterweight Assembly 2254
How to Install Counterweight Assembly 2255
Hydraulic System 2258
Remove and Install Center Swivel Joint Assembly 2258
How to Remove Center Swivel Joint Assembly 2258
How to Install Center Swivel Joint Assembly 2261
Disassemble and Assemble Center Swivel Joint Assembly 2264
How to Disassemble Center Swivel Joint Assembly 2264
How to Assemble Center Swivel Joint Assembly 2265
Remove and Install Hydraulic Tank Assembly 2267
How to Remove Hydraulic Tank Assembly 2267
How to Install Hydraulic Tank Assembly 2274
Remove and Install Main Pump Assembly 2282
How to Remove Main Pump Assembly 2282
How to Install Main Pump Assembly 2284
Remove and Install Control Valve Assembly 2287
How to Remove Control Valve Assembly 2287
How to Install Control Valve Assembly 2290
Disassemble and Assemble Control Valve Assembly 2294
How to Assemble Control Valve Assembly 2294
How to Replace Pressure Reducing Valve Cartridge Assembly 2296
Disassemble and Assemble Work Equipment PPC Valve Assembly 2299
How to Disassemble Work Equipment PPC Valve Assembly 2299
How to Assemble Work Equipment PPC Valve Assembly 2300
Work Equipment 2302
Remove and Install Work Equipment Assembly 2302
How to Remove Work Equipment Assembly 2302
How to Install Work Equipment Assembly 2305
Remove and Install Boom Anti-drop Valve Assembly 2309
How to Remove Boom Anti-drop Valve Assembly 2309
How to Install Boom Anti-drop Valve Assembly 2311
Remove and Install Arm Anti-Drop Valve Assembly 2312
How to Remove Arm Anti-Drop Valve Assembly 2312
How to Install Arm Anti-Drop Valve Assembly 2314
Disassemble and Assemble Anti-Drop Valve Assembly 2315
How to Disassemble Anti-Drop Valve Assembly 2315
How to Assemble Anti-Drop Valve Assembly 2315
Disassemble and Assemble Work Equipment Cylinder Assembly 2316
How to Disassemble Work Equipment Cylinder Assembly 2317
How to Assemble Work Equipment Cylinder Assembly 2319
CAB Related Parts 2325
Remove and Install Operator Cab Assembly 2325
How to Remove Operator Cab Assembly 2325
How to Install Operator Cab Assembly 2332
Remove and Install Operator Cab Glass (Adhered Glass) 2340
How to Remove Operator Cab Glass (Adhered Glass) 2342
How to Install Operator Cab Glass (Adhered Glass) 2342
Remove and Install Front Window Assembly 2352
How to Remove Front Window Assembly 2352
How to Install Front Window Assembly 2355
Remove and Install Floor Frame Assembly 2361
How to Remove Floor Frame Assembly 2361
How to Install Floor Frame Assembly 2365
Remove and Install Air Conditioner Unit Assembly 2370
How to Remove Air Conditioner Unit Assembly 2370
How to Install Air Conditioner Unit Assembly 2374
Remove and Install Operator Seat 2380
How to Remove Operator Seat 2380
How to Install Operator Seat 2382
How to Remove and Install Seat Belt 2385
How to Remove Seat Belt 2385
How to Install Seatbelt 2385
Remove and Install Work Equipment Control Lever Assembly 2387
How to Remove Work Equipment Control Lever Assembly 2387
How to Install Work Equipment Control Lever Assembly 2393
Remove and Install Front Wiper Assembly 2402
How to Remove Front Wiper Assembly 2402
How to Install Front Wiper Assembly 2407
Electrical System 2416
Remove and Install Engine Controller Assembly 2416
How to Remove Engine Controller Assembly 2416
How to Install Engine Controller Assembly 2418
Remove and Install Pump Controller Assembly 2421
How to Remove Pump Controller Assembly 2421
How to Install Pump Controller Assembly 2424
Remove and Install KomVision Controller Assembly 2427
How to Remove KomVision Controller Assembly 2427
How to Install KomVision Controller Assembly 2428
Remove and Install Machine Monitor Assembly 2430
How to Remove Machine Monitor Assembly 2430
How to Install Machine Monitor Assembly 2432
Remove and Install Pump Swash Plate Sensor 2436
How to Remove Pump Swash Plate Sensor 2436
How to Install Pump Swash Plate Sensor 2436
Remove and Install Mass Air Flow and Temperature Sensor 2438
How to Remove Mass Air Flow and Temperature Sensor 2438
How to Install Mass Air Flow and Temperature Sensor 2439
Remove and Install KCCV Crankcase Pressure Sensor 2441
How to Remove KCCV Crankcase Pressure Sensor 2441
How to Install KCCV Crankcase Pressure Sensor 2442
Remove and Install SCR Temperature Sensor 2444
How to Remove SCR Temperature Sensor 2444
How to Install SCR Temperature Sensor 2445
Remove and Install KomVision Camera 2447
How to Remove KomVision Camera 2447
How to Install KomVision Camera 2448
Remove and Install KOMTRAX Terminal Assembly 2450
How to Remove KOMTRAX Terminal Assembly 2450
How to Install KOMTRAX Terminal Assembly 2452
60 Maintenance Standard 2455
Table of Contents 2456
Engine and Cooling System 2457
Maintenance Standard for Engine Mount 2457
Maintenance Standard for Cooling System 2458
Power Train 2460
Maintenance Standard for Swing Circle 2460
Maintenance Standard for Swing Machinery 2461
Maintenance Standard for Final Drive 2463
Maintenance Standard for Sprocket 2465
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2466
Undercarriage and Frame 2467
Maintenance Standard for Track Frame and Idler Cushion 2467
Maintenance Standard for Idler 2469
Maintenance Standard for Track Roller 2471
Maintenance Standard for Carrier Roller 2472
Maintenance Standard for Track Shoes 2473
Maintenance Standard for Triple Shoes 2476
Hydraulic System 2477
Maintenance Standard for Hydraulic Tank 2477
Maintenance Standard for Main Pump 2478
Maintenance Standard for PC-EPC Valve 2480
Maintenance Standard for Travel Motor 2481
Maintenance Standard for Control Valve 2484
Maintenance Standard for Boom Anti-Drop Valve 2495
Maintenance Standard for Arm Anti-Drop Valve 2497
Maintenance Standard for Work Equipment and Swing PPC Valve 2499
Maintenance Standard for Travel PPC Valve 2502
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2505
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2506
Maintenance Standard for 2nd-Line Attachment PPC Valve 2508
Maintenance Standard for Solenoid Valve 2510
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2511
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2512
Maintenance Standard for Center Swivel Joint 2513
Work Equipment 2514
Maintenance Standard for Work Equipment Linkage 2514
Dimensions of Arm 2519
Dimensions of Bucket 2521
Maintenance Standard for Boom Cylinder 2523
Maintenance Standard for Arm Cylinder 2524
Maintenance Standard for Bucket Cylinder 2525
80 Appendix 2527
Table of Contents 2528
Precautions Before Work 2530
Air Conditioner System 2531
Precautions for Refrigerant 2531
Air Conditioner Component 2532
Specifications of Air Conditioner 2534
Structure and Function of Refrigeration Cycle 2535
Outline of Refrigeration Cycle 2536
Component Parts of Air Conditioner System 2538
Air Conditioner Unit 2538
Configuration Diagram of Air Conditioner Unit 2538
Function of Air Conditioner Unit 2540
Component Parts of Air Conditioner Unit 2542
Function of Evaporator as Air Conditioner Unit Component 2543
Function of Heater Core as Air Conditioner Unit Component 2543
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2543
Function of Servo Motor as Air Conditioner Unit Component 2543
Structure of Expansion Valve as Air Conditioner Unit Component 2544
Function of Expansion Valve as Air Conditioner Unit Component 2544
Operate Expansion Valve as Air Conditioner Unit Component 2544
Function of Dual Pressure Switch 2545
Air Conditioner Controller 2546
Structure of Air Conditioner Controller 2546
Compressor 2547
Structure of Compressor 2547
Specifications of Compressor 2547
Function of Compressor 2547
Condenser 2548
Structure of Condenser 2548
Specifications of Condenser 2548
Function of Condenser 2548
Air Conditioner Related Sensors 2550
Structure of Sunlight Sensor 2550
Function of Sunlight Sensor 2550
Structure of Outside Temperature Sensor 2550
Function of Outside Air Temperature Sensor 2550
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2552
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2554
System Diagram of Air Conditioner 2556
Input and Output Signals of Air Conditioner Controller 2557
Function of Air Conditioner Controller 2558
Locations of Air Conditioner Parts and Layout of Connectors 2559
Examine Air Leakage (Duct) 2563
How to Examine Air Leakage (Duct) 2563
Examine Air Conditioner with Self-Diagnosis Function 2565
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2566
Examine Vent (Mode) Changeover 2567
How to Examine Vent (Mode) Changeover 2567
Examine Fresh/Recirc Air Changeover 2569
How to Examine Fresh/Recirc Air Changeover 2569
Examine Sunlight Sensor 2570
How to Examine Sunlight Sensor 2570
Examine Refrigerant (Dual) Pressure Switch 2571
How to Examine Refrigerant (Dual) Pressure Switch 2571
Examine Relay 2572
How to Examine Relay 2572
Air Conditioner Troubleshooting Chart 1 2573
Air Conditioner Troubleshooting Chart 2 2574
Information Shown in Troubleshooting Table 2577
Failure Code [879AKA] 2578
Failure Code [879AKB] 2579
Failure Code [879BKA] 2580
Failure Code [879BKB] 2582
Failure Code [879CKA] 2584
Failure Code [879CKB] 2585
Failure Code [879DKZ] 2586
Failure Code [879EMC] 2588
Failure Code [879FMC] 2589
Failure Code [879GKX] 2590
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2592
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2594
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2597
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2599
Troubleshooting by Gauge Pressure 2601
Connect Service Tool 2604
How to Connect Service Tool 2604
Precautions for Disconnection and Connection of Air Conditioner Piping 2606
Handle Compressor Oil 2608
How to Replace Desiccant 2610
90 Circuit Diagrams 2613
Table of Contents 2614
Hydraulic Circuit Diagram 2615
Symbols Used in Hydraulic Circuit Diagram 2615
Hydraulic Circuit Diagram (1/2) 2619
Hydraulic Circuit Diagram (2/2) 2621
Electrical Circuit Diagram 2623
Symbols Used in Electric Circuit Diagram 2623
Electrical Circuit Diagram (1/8) 2627
Electrical Circuit Diagram (2/8) 2629
Electrical Circuit Diagram (3/8) 2631
Electrical Circuit Diagram (4/8) 2633
Electrical Circuit Diagram (5/8) 2635
Electrical Circuit Diagram (6/8) 2637
Electrical Circuit Diagram (7/8) 2639
Electrical Circuit Diagram (8/8) 2641
Index 2643

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24