Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06607-18 – PDF DOWNLOAD 

Description

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06607-18 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06607-18 – PDF DOWNLOAD 

Language : English
Pages : 2594
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06607-18 – PDF DOWNLOAD 

SERIAL NUMBERS 35001 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 SEN06607-18 – PDF DOWNLOAD 

SERIAL NUMBERS 35001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 20
Foreword, Safety, Basic Information 23
How to Read the Shop Manual 23
Safety Notice for Operation 25
Precautions to Prevent Fire 33
Procedures If Fire Occurs 35
Precautions for Disposing of Waste Materials 36
Procedures for Exhaust Gas Regulations 37
Precautions for DEF 38
General Character and Precautions for Handling 38
Precautions for Adding 38
Precautions for Storage 38
Precautions for Fire Hazard and Leakage 38
Other Precautions 38
Store DEF 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
How to Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
How to Disconnect and Connect Connector with Lock to Pull 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
01 Specifications 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: PC170LC-11 91
Working Range Drawings 93
Working Range Drawings: PC170LC-11 93
Specifications 94
Specification: PC170LC-11 94
Weight Table 97
Weight Table: PC170LC-11 97
Table of Fuel, Coolant, and Lubricants 99
10 Structure and Function 101
Table of Contents 102
Urea SCR System 105
Layout Drawing of Urea SCR System 105
Urea SCR System Diagram 110
Function of Urea SCR System 111
Function of DEF System 111
Inducement Strategy 113
Component Parts of Urea SCR System 130
DEF Mixing Tube 130
SCR Assembly 131
DEF Tank 133
DEF Pump 135
DEF Injector 136
DEF Hose 137
DEF Tank Heating Valve 138
Boot-up System 139
Layout Drawing of Boot-up System 139
System Operating Lamp System 141
System Diagram of System Operating Lamp System 141
Function of Operation Lamp System 141
Battery Disconnect Switch 142
Function of Battery Disconnect Switch 142
Engine System 143
Layout Drawing of Engine System 143
Specifications of Engine System 144
Function of Engine System 144
Engine Control System 145
System Diagram of Engine Control 145
Function of Engine Control System 146
Auto-Deceleration System 148
System Diagram of Auto-Deceleration System 148
Function of Auto-Deceleration System 148
Operation of Auto-Deceleration System 149
Engine Automatic Warm-up System 150
System Diagram of Engine Automatic Warm-up System 150
Function of Engine Automatic Warm-up System 151
Overheat Prevention System 152
Overheat Prevention System Diagram 152
Function of Overheat Prevention System 153
Turbocharger Protection System 155
System Diagram of Turbocharger Protection System 155
Function of Turbocharger Protection System 156
Automatic Idle Stop System 157
System Diagram of Automatic Idle Stop System 157
Function of Automatic Idle Stop System 157
Component Parts of Engine System 160
VGT 160
EGR System 163
EGR Valve 165
EGR Cooler 167
KCCV System 169
KCCV Ventilator 171
KDOC 173
Cooling System 176
Layout Drawing of Cooling System 176
Specifications of Cooling System 177
Fan Speed Control System of Fan Clutch 178
Fan Speed Control System Diagram of Fan Clutch 178
Function of Fan Speed Control System of Fan Clutch 179
Engine Output Control System of Fan Clutch 180
Engine Output Control System Diagram of Fan Clutch 180
Function of Engine Output Control System of Fan Clutch 180
Component Parts of Cooling System 182
Fan Clutch 182
Control System 183
Layout Drawing of Control System 183
Machine Monitor System 186
System Diagram of Machine Monitor System 186
Function of Machine Monitor System 186
KomVision System 188
Layout Drawing of KomVision System 188
System Diagram of KomVision System 190
Function of KomVision System 190
KOMTRAX System 192
System Diagram of KOMTRAX System 192
Function of KOMTRAX System 192
Component Parts of Control System 193
Machine Monitor 193
KomVision Controller 208
KomVision Camera 212
KOMTRAX Terminal 213
Pump Controller 215
Resistor for PC-EPC Valve 220
CAN Terminating Resistor 221
Engine Controller 222
Fuel Control Dial 229
Hydraulic System 231
Layout Drawing of Hydraulic System 231
CLSS 235
Structure of CLSS 235
Function of CLSS 236
Engine and Pump Combined Control System 238
Engine and Pump Combined Control System Diagram 238
Function of Engine and Pump Combined Control System 239
Pump and Valve Control System 244
Pump and Valve Control System Diagram 244
Function of Pump and Valve Control System 245
Component Parts of Hydraulic System 247
Hydraulic Tank 247
Main Pump 249
Control Valve 272
Work Equipment System 335
Layout Drawing of Work Equipment System 335
One-Touch Power Maximizing System 339
System Diagram of One-Touch Power Maximizing System 339
Function of One-Touch Power Maximizing System 339
PPC Lock System 341
System Diagram of PPC Lock 341
Function of PPC Lock System 341
Work Equipment and Travel Automatic Lock System 342
System Diagram of Lock Lever Automatic Lock System 342
Function of Work Equipment and Travel Automatic Lock System 342
Operation of Lock Lever Automatic Lock System 343
Attachment Oil Flow Adjuster System 344
Attachment Oil Flow Adjuster System Diagram 344
Function of Attachment Oil Flow Adjuster System 345
Component Parts of Work Equipment System 346
Work Equipment and Swing PPC Valve 346
1st-Line Attachment PPC Valve (with EPC Valve) 352
2nd-Line Attachment PPC Valve 361
Solenoid Valve 363
Boom Anti-drop Valve 365
Arm Anti-Drop Valve 369
Attachment Circuit Selector Valve (For High Pressure) 374
Attachment Circuit Selector Valve (For Low Pressure) 376
Pilot Circuit Accumulator 378
Attachment Circuit Accumulator 379
Swing System 380
Layout Drawing of Swing System 380
Swing Control System Diagram 384
Function of Swing Control System 384
Component Parts of Swing System 387
Swing Motor 387
Swing Machinery 391
Swing Circle 393
Travel System 395
Layout Drawing of Travel System 395
System Diagram of Travel Control System 398
Function of Travel Control System 399
Component Parts of Travel System 400
Travel Motor 400
Final Drive 412
Travel PPC Valve 414
Center Swivel Joint 418
Undercarriage and Frame 420
Layout Drawing of Undercarriage 420
Specifications of Undercarriage 421
Work Equipment 422
Structure of Work Equipment 422
Function of Work Equipment 423
Work Equipment Clearance Adjustment Shim 424
Function of Work Equipment Clearance Adjustment Shim 424
Bucket Clearance Adjustment Shim 425
Function of Bucket Clearance Adjustment Shim 425
CAB Related Parts 426
ROPS CAB 426
Structure of ROPS CAB 426
Function of ROPS CAB 426
CAB Mount 427
Structure of CAB Mount 427
Function of CAB Mount 427
CAB Tipping Stopper 428
Structure of CAB Tipping Stopper 428
Function of CAB Tipping Stopper 428
20 Standard Value Table 429
Table of Contents 430
Standard Value Table for Engine 431
Standard Value Table for Engine: PC170LC-11 431
Standard Value Table for Machine 435
Standard Value Table for Machine: PC170LC-11 435
Machine Posture and Procedures to Measure Performance 448
30 Testing and Adjusting 453
Table of Contents 454
Precautions Before Work 457
Related Information on Testing and Adjusting 458
Tools for Testing and Adjusting 458
Sketch of Tools for Testing and Adjusting 465
Engine and Cooling System 467
Examine Engine Speed 467
How to Examine Engine Speed 467
Examine Boost Pressure 469
How to Examine Boost Pressure on Machine Monitor 469
How to Examine Boost Pressure by Testing Tool 470
Examine Exhaust Gas Color 471
How to Examine Exhaust Gas Color with the Handy Smoke Checker 471
How to Examine Exhaust Gas Color with Smoke Meter 472
Examine and Adjust Valve Clearance 473
How to Examine Valve Clearance 473
How to Adjust Valve Clearance 474
Examine Compression Pressure 476
How to Examine Compression Pressure 476
Examine Blowby Pressure 481
How to Examine Blowby Pressure 481
Examine Engine Oil Pressure 483
How to Examine Engine Oil Pressure 483
Examine Fuel Pressure 484
How to Examine Fuel Pressure 485
Examine Fuel Discharge, Return and Leakage 489
How to Examine Fuel Discharge, Return, and Leakage 490
Bleed Air from Fuel System 494
How to Bleed Air from Fuel System 494
Examine Fuel Circuit for Leakage 495
How to Examine Fuel System for Leakage 495
Handle Cylinder Cut-out Mode Operation 497
Handle No-Injection Cranking Operation 498
Examine and Adjust Air Conditioner Compressor Belt Tension 499
How to Examine Air Conditioner Compressor Belt 499
How to Adjust Air Conditioner Compressor Belt 499
Examine Fan Belt and Alternator Belt 501
How to Examine Fan Belt and Alternator Belt 501
Examine Automatic Tensioner 502
How to Examine Automatic Tensioner 502
Examine Cooling Fan Speed 503
How to Examine Cooling Fan Speed 503
Examine SCR Related Functions 504
Examine DEF Pump Raised Pressure 508
Examine Injection Volume from DEF Injector 511
Examine DEF Line Heater Relay 1 515
Examine DEF Line Heater Relay 2 518
Examine DEF Pump Heater Relay 521
Examine DEF Tank Heater Valve 525
Examine SCR Denitration Efficiency 527
Clean DEF Tank 531
How to Clean DEF Tank 531
Clean DEF Pump 535
How to Clean DEF Pump 535
Bleed Air from Coolant Circuit of DEF Tank 542
How to Bleed Air from Coolant Circuit of DEF Tank 542
Power Train 544
Examine Swing Circle Bearing Clearance 544
How to Examine Swing Circle Bearing Clearance 544
Undercarriage and Frame 545
Examine and Adjust Track Tension 545
How to Examine Track Tension 545
How to Adjust Track Tension 545
Hydraulic System 547
Release Remained Pressure in Hydraulic Circuit 547
How to Release Remained Pressure from Hydraulic Tank 547
How to Release Remained Pressure in Hydraulic Cylinder Circuit 547
How to Release Remained Pressure from Swing Motor Circuit 549
How to Release Remained Pressure from Travel Motor Circuit 549
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 550
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 550
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 556
Examine Oil Pressure of Control Circuit 558
How to Examine Oil Pressure in Control Circuit 558
Examine and adjust oil pressure in pump PC control circuit 560
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 560
How to Examine PC-EPC Valve Outlet Pressure 561
How to Adjust Oil Pressure in Pump PC Control Circuit 562
Examine and Adjust Oil Pressure in Pump LS Control Circuit 564
How to Examine LS Differential Pressure with Machine Monitor 564
How to Examine LS Differential Pressure by Testing Tool 566
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 568
How to Adjust LS Valve 569
Examine Outlet Pressure of Solenoid Valve 570
How to Examine Outlet Pressure of Solenoid Valve 570
Operating Condition of Solenoid Valve 571
Examine PPC Valve Outlet Pressure 574
How to Examine Outlet Pressure in PPC Valve 574
Adjust Play of Work Equipment and Swing PPC Valves 576
How to Adjust Play of Work Equipment and Swing PPC Valves 576
Examine Pump Swash Plate Sensor 577
How to Examine pump swash plate sensor 577
Examine and Adjust Travel Deviation 578
How to Examine Travel Deviation 578
How to Adjust Travel Deviation 578
Examine Parts Which Cause Hydraulic Drift of Work Equipment 581
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 581
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 581
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 582
Examine Oil Leakage 583
How to Examine Oil Leakage from Boom Cylinder 583
How to Examine Oil Leakage from Arm Cylinder 583
How to Examine Oil Leakage from Bucket Cylinder 584
How to Examine Oil Leakage from Swing Motor 585
How to Examine Oil Leakage from Travel Motor 585
Bleed Air from Hydraulic System 586
How to Bleed Air from Hydraulic System 587
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 590
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 590
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 594
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 594
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 598
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 598
CAB Related Parts 605
Examine CAB Tipping Stopper 605
How to Examine Cab Tipping Stopper 605
How to Adjust Mirrors 606
Procedure to Adjust Machine Left Front Mirror (A) 606
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 607
Procedure to Adjust Machine Right Front Mirror (B) 608
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 609
Procedure to Adjust Machine Right Side Mirror (C) 611
Electrical System 612
Set and Operate Machine Monitor 612
Operator Mode 616
Function to Show Technician Identification Status Screen 616
Function to Show Operator Identification Input Screen 616
Examine Function by LCD (Liquid Crystal Display) 617
Examine Function of Service Meter 617
Usage Limitation and Maintenance Password Change Function 617
Service Mode 620
How to Operate Service Mode 620
How to See Pre-defined Monitoring Information 621
How to Examine Self-Define Monitor Information 628
Abnormality Record Menu 639
How to See Maintenance Record 643
Maintenance Mode Setting 644
How to Set Phone Number Entry 648
Default Menu 650
Diagnostic Tests Menu 658
Adjustment Menu 665
No-Injection Cranking Operation 683
KOMTRAX Settings Menu 685
How to Show Service Message 687
How to Start Up KOMTRAX Terminal 689
Adjust Rearview Camera Angle 694
How to Adjust Rearview Camera Angle 694
Adjust KomVision Camera Angle 697
How to Adjust KomVision Camera Angle 698
Adjust KomVision Related Function 702
Setting of KomVision (Main Setting) 703
Setting of KomVision (Camera Setting) 705
Setting of KomVision (Camera Calibration) 706
KomVision screen – Check 12 m visibility 719
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: PC170LC-11 727
40 Troubleshooting 737
Table of Contents 738
Precautions Before Work 748
Related Information to Troubleshooting 749
General Troubleshooting Points 749
Troubleshooting Points for Urea SCR System 750
Sequence of Events in Troubleshooting 764
Checks Before Troubleshooting 766
Inspection Procedure Before Troubleshooting 768
Walk-Around Check 768
Test in Accordance with Testing Procedure 770
Examine Fuel Level and Type 770
Examine for Impure Ingredient in Fuel 770
Examine Fuel Prefilter 771
Examine Water Separator, Drain Water and Sediment 771
How to Replace Fuel Prefilter Cartridge 772
Examine Fuel Main Filter 774
Examine Engine Oil Level (Oil Quantity in Oil Pan) 775
Examine Coolant Level (Reservoir Tank) 776
Examine Air Cleaner Clogging 777
Clean Outer Element 777
Replace Element 780
Examine Hydraulic Oil Level 782
Examine Hydraulic Oil Strainer 783
Examine Hydraulic Oil Filter 784
Examine Oil Level in Swing Machinery Case 785
Examine Oil Level in Damper Case 786
Examine Oil Level in Final Drive Case 786
Bleed Air from Fuel System 787
Bleed Air from Hydraulic System 787
How to Examine Electric Equipment 787
Preparation for Troubleshooting of Electrical System 793
Preparation for Troubleshooting of Machine Monitor 793
Preparation for Troubleshooting of Engine Controller 793
Preparation for Troubleshooting of Pump Controller 793
Preparation for Troubleshooting of KOMTRAX Terminal 794
How to Disconnect and Connect Connector with a Special Lock 794
Procedure for Troubleshooting 798
Symptom and Troubleshooting Numbers 801
Information Shown in Troubleshooting Table 805
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 807
Connector List and Layout 810
Connector Contact Connection Table 822
T-Branch Box and T-Branch Adapter Table 862
Fuse Location Table 868
Precautions When You Replace KDOC 871
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 872
Failure Code Table 874
Troubleshooting by Failure Code (Display of Code) 890
Failure Code [879AKA] 890
Failure Code [879AKB] 891
Failure Code [879BKA] 892
Failure Code [879BKB] 894
Failure Code [879CKA] 896
Failure Code [879CKB] 897
Failure Code [879DKZ] 898
Failure Code [879EMC] 900
Failure Code [879FMC] 901
Failure Code [879GKX] 902
Failure Code [989L00] 904
Failure Code [989M00] 905
Failure Code [989N00] 906
Failure Code [A1U0N3] 907
Failure Code [A1U0N4] 909
Failure Code [A900FR] 911
Failure Code [A900N6] 912
Failure Code [A900NY] 913
Failure Code [AA10NX] 914
Failure Code [AB00KE] 916
Failure Code [AQ10MB] 919
Failure Code [AQ10N3] 921
Failure Code [AS00N3] 923
Failure Code [AS00R2] 925
Failure Code [AS00R3] 926
Failure Code [AS00R4] 927
Failure Code [AS00R5] 928
Failure Code [AS00R6] 929
Failure Code [AS00ZK] 930
Failure Code [AS10KM] 931
Failure Code [AS10NR] 932
Failure Code [AS10NT] 934
Failure Code [B@BAZG] 935
Failure Code [B@BAZK] 936
Failure Code [B@BCNS] 938
Failure Code [B@BCZK] 939
Failure Code [B@HANS] 941
Failure Code [CA115] 942
Failure Code [CA122] 943
Failure Code [CA123] 945
Failure Code [CA131] 947
Failure Code [CA132] 949
Failure Code [CA144] 951
Failure Code [CA145] 953
Failure Code [CA153] 955
Failure Code [CA154] 958
Failure Code [CA187] 961
Failure Code [CA221] 963
Failure Code [CA222] 965
Failure Code [CA227] 967
Failure Code [CA234] 969
Failure Code [CA238] 970
Failure Code [CA239] 971
Failure Code [CA249] 972
Failure Code [CA256] 974
Failure Code [CA271] 976
Failure Code [CA272] 978
Failure Code [CA295] 980
Failure Code [CA322] 981
Failure Code [CA324] 983
Failure Code [CA331] 985
Failure Code [CA332] 987
Failure Code [CA343] 989
Failure Code [CA351] 990
Failure Code [CA352] 992
Failure Code [CA356] 994
Failure Code [CA357] 996
Failure Code [CA386] 998
Failure Code [CA428] 999
Failure Code [CA429] 1001
Failure Code [CA435] 1003
Failure Code [CA441] 1005
Failure Code [CA442] 1007
Failure Code [CA451] 1009
Failure Code [CA452] 1011
Failure Code [CA488] 1013
Failure Code [CA515] 1014
Failure Code [CA516] 1016
Failure Code [CA553] 1018
Failure Code [CA555] 1019
Failure Code [CA556] 1020
Failure Code [CA559] 1021
Failure Code [CA595] 1024
Failure Code [CA687] 1026
Failure Code [CA689] 1028
Failure Code [CA691] 1030
Failure Code [CA692] 1032
Failure Code [CA697] 1034
Failure Code [CA698] 1035
Failure Code [CA731] 1036
Failure Code [CA778] 1038
Failure Code [CA1117] 1043
Failure Code [CA1664] 1045
Failure Code [CA1669] 1047
Failure Code [CA1673] 1048
Failure Code [CA1677] 1049
Failure Code [CA1678] 1050
Failure Code [CA1682] 1051
Failure Code [CA1683] 1053
Failure Code [CA1684] 1055
Failure Code [CA1686] 1057
Failure Code [CA1691] 1058
Failure Code [CA1694] 1060
Failure Code [CA1695] 1062
Failure Code [CA1696] 1063
Failure Code [CA1712] 1065
Failure Code [CA1713] 1068
Failure Code [CA1714] 1070
Failure Code [CA1715] 1071
Failure Code [CA1776] 1072
Failure Code [CA1777] 1074
Failure Code [CA1843] 1077
Failure Code [CA1844] 1079
Failure Code [CA1885] 1081
Failure Code [CA1887] 1083
Failure Code [CA1896] 1085
Failure Code [CA1898] 1086
Failure Code [CA1938] 1088
Failure Code [CA1942] 1090
Failure Code [CA1961] 1091
Failure Code [CA1962] 1092
Failure Code [CA2185] 1093
Failure Code [CA2186] 1094
Failure Code [CA2198] 1096
Failure Code [CA2249] 1098
Failure Code [CA2272] 1099
Failure Code [CA2288] 1101
Failure Code [CA2311] 1102
Failure Code [CA2349] 1103
Failure Code [CA2353] 1105
Failure Code [CA2357] 1107
Failure Code [CA2373] 1108
Failure Code [CA2374] 1110
Failure Code [CA2375] 1112
Failure Code [CA2376] 1114
Failure Code [CA2387] 1117
Failure Code [CA2554] 1118
Failure Code [CA2634] 1120
Failure Code [CA2635] 1122
Failure Code [CA2636] 1123
Failure Code [CA2637] 1125
Failure Code [CA2771] 1127
Failure Code [CA2961] 1131
Failure Code [CA2973] 1132
Failure Code [CA2976] 1133
Failure Code [CA3142] 1135
Failure Code [CA3143] 1136
Failure Code [CA3144] 1137
Failure Code [CA3146] 1139
Failure Code [CA3147] 1140
Failure Code [CA3148] 1141
Failure Code [CA3151] 1143
Failure Code [CA3165] 1148
Failure Code [CA3228] 1150
Failure Code [CA3229] 1153
Failure Code [CA3231] 1155
Failure Code [CA3232] 1157
Failure Code [CA3235] 1161
Failure Code [CA3239] 1163
Failure Code [CA3241] 1166
Failure Code [CA3242] 1169
Failure Code [CA3251] 1172
Failure Code [CA3313] 1174
Failure Code [CA3314] 1175
Failure Code [CA3315] 1176
Failure Code [CA3419] 1178
Failure Code [CA3421] 1180
Failure Code [CA3497] 1182
Failure Code [CA3498] 1183
Failure Code [CA3545] 1184
Failure Code [CA3547] 1186
Failure Code [CA3558] 1187
Failure Code [CA3559] 1189
Failure Code [CA3562] 1191
Failure Code [CA3563] 1193
Failure Code [CA3567] 1196
Failure Code [CA3568] 1199
Failure Code [CA3571] 1203
Failure Code [CA3572] 1205
Failure Code [CA3574] 1207
Failure Code [CA3575] 1209
Failure Code [CA3577] 1211
Failure Code [CA3578] 1213
Failure Code [CA3582] 1215
Failure Code [CA3583] 1221
Failure Code [CA3596] 1223
Failure Code [CA3649] 1226
Failure Code [CA3681] 1228
Failure Code [CA3682] 1232
Failure Code [CA3713] 1236
Failure Code [CA3717] 1239
Failure Code [CA3718] 1240
Failure Code [CA3724] 1241
Failure Code [CA3725] 1242
Failure Code [CA3741] 1245
Failure Code [CA3748] 1246
Failure Code [CA3755] 1249
Failure Code [CA3866] 1251
Failure Code [CA3868] 1254
Failure Code [CA4152] 1257
Failure Code [CA4155] 1261
Failure Code [CA4156] 1263
Failure Code [CA4157] 1266
Failure Code [CA4159] 1268
Failure Code [CA4164] 1269
Failure Code [CA4165] 1271
Failure Code [CA4166] 1273
Failure Code [CA4168] 1274
Failure Code [CA4169] 1277
Failure Code [CA4171] 1279
Failure Code [CA4249] 1282
Failure Code [CA4251] 1284
Failure Code [CA4261] 1287
Failure Code [CA4277] 1290
Failure Code [CA4459] 1294
Failure Code [CA4461] 1296
Failure Code [CA4533] 1299
Failure Code [CA4534] 1300
Failure Code [CA4731] 1301
Failure Code [CA4732] 1302
Failure Code [CA4739] 1303
Failure Code [CA4768] 1304
Failure Code [CA4769] 1306
Failure Code [CA4842] 1308
Failure Code [CA4952] 1311
Failure Code [CA5115] 1313
Failure Code [CA5179] 1316
Failure Code [CA5181] 1318
Failure Code [CA5387] 1320
Failure Code [CA5388] 1322
Failure Code [CA5389] 1325
Failure Code [CA5391] 1327
Failure Code [CA5392] 1331
Failure Code [CA5393] 1333
Failure Code [CA5394] 1335
Failure Code [CA5395] 1337
Failure Code [CA5396] 1340
Failure Code [CA5631] 1341
Failure Code [CA5632] 1343
Failure Code [CA5938] 1344
Failure Code [D110KB] 1346
Failure Code [D19JKZ] 1348
Failure Code [D811MC] 1351
Failure Code [D862KA] 1352
Failure Code [D8ALKA] 1353
Failure Code [D8ALKB] 1355
Failure Code [D8AQKR] 1357
Failure Code [DA20MC] 1361
Failure Code [DA22KK] 1362
Failure Code [DA25KP] 1365
Failure Code [DA29KQ] 1368
Failure Code [DA2LKA] 1370
Failure Code [DA2LKB] 1372
Failure Code [DA2QKR] 1374
Failure Code [DA2RKR] 1379
Failure Code [DAF0KM] 1384
Failure Code [DAF0MB] 1385
Failure Code [DAF0MC] 1386
Failure Code [DAF8KB] 1387
Failure Code [DAF9KQ] 1389
Failure Code [DAFGMC] 1390
Failure Code [DAFLKA] 1391
Failure Code [DAFLKB] 1393
Failure Code [DAFQKR] 1395
Failure Code [DAZ9KQ] 1399
Failure Code [DAZQKR] 1400
Failure Code [DB2QKR] 1404
Failure Code [DB2RKR] 1409
Failure Code [DBP0KM] 1414
Failure Code [DBP0KT] 1415
Failure Code [DBP5KB] 1416
Failure Code [DBP5KY] 1419
Failure Code [DBPQKR] 1422
Failure Code [DDNRKA] 1427
Failure Code [DDNRKY] 1429
Failure Code [DDNS00] 1431
Failure Code [DFB1KZ] 1433
Failure Code [DFB2KZ] 1435
Failure Code [DFB3L8] 1437
Failure Code [DFB4L8] 1439
Failure Code [DFB5KZ] 1441
Failure Code [DFB6KZ] 1443
Failure Code [DGH2KA] 1445
Failure Code [DGH2KB] 1447
Failure Code [DHA4KA] 1449
Failure Code [DHPAMA] 1451
Failure Code [DHPBMA] 1454
Failure Code [DHS3MA] 1457
Failure Code [DHS4MA] 1460
Failure Code [DHS5MA] 1463
Failure Code [DHS8MA] 1465
Failure Code [DHS9MA] 1468
Failure Code [DHSAMA] 1471
Failure Code [DHSBMA] 1474
Failure Code [DHSCMA] 1477
Failure Code [DHSDMA] 1480
Failure Code [DKR0MA] 1483
Failure Code [DKULKA] 1486
Failure Code [DKULKB] 1488
Failure Code [DKULKY] 1490
Failure Code [DLM5KA] 1492
Failure Code [DLM5MB] 1495
Failure Code [DR10KA] 1497
Failure Code [DR12KA] 1500
Failure Code [DR20KA] 1502
Failure Code [DR21KX] 1504
Failure Code [DR30KA] 1506
Failure Code [DR31KX] 1508
Failure Code [DR40KA] 1510
Failure Code [DUMBKA] 1512
Failure Code [DUMBKB] 1514
Failure Code [DV20KB] 1516
Failure Code [DW43KA] 1518
Failure Code [DW43KB] 1520
Failure Code [DW43KY] 1522
Failure Code [DW45KA] 1524
Failure Code [DW45KB] 1527
Failure Code [DW45KY] 1530
Failure Code [DW4CKY] 1532
Failure Code [DW91KA] 1534
Failure Code [DW91KB] 1536
Failure Code [DW91KY] 1538
Failure Code [DWA2KA] 1540
Failure Code [DWA2KB] 1542
Failure Code [DWA2KY] 1544
Failure Code [DWJ0KA] 1546
Failure Code [DWJ0KB] 1548
Failure Code [DWJ0KY] 1550
Failure Code [DWK0KA] 1552
Failure Code [DWK0KB] 1554
Failure Code [DWK0KY] 1556
Failure Code [DWK2KA] 1558
Failure Code [DWK2KB] 1560
Failure Code [DWK2KY] 1562
Failure Code [DWN5KA] 1564
Failure Code [DWN5KB] 1567
Failure Code [DWN5KY] 1570
Failure Code [DWNSKA] 1572
Failure Code [DWNSKB] 1574
Failure Code [DWNSKY] 1576
Failure Code [DXA8KA] 1577
Failure Code [DXA8KB] 1579
Failure Code [DXE4KA] 1581
Failure Code [DXE4KB] 1583
Failure Code [DXE4KY] 1585
Failure Code [DXE7KA] 1587
Failure Code [DXE7KB] 1589
Failure Code [DXE7KY] 1591
Failure Code [DXE8KA] 1593
Failure Code [DXE8KB] 1595
Failure Code [DXE8KY] 1597
Failure Code [DXE9KA] 1599
Failure Code [DXE9KB] 1601
Failure Code [DXE9KY] 1603
Failure Code [DXEAKA] 1605
Failure Code [DXEAKB] 1607
Failure Code [DXEAKY] 1609
Failure Code [DY20KA] 1611
Failure Code [DY20MA] 1613
Failure Code [DY2CKB] 1615
Failure Code [DY2DKB] 1618
Failure Code [DY2EKB] 1620
Troubleshooting of Electrical System (E-Mode) 1622
E-1 Engine Does Not Start (Engine Does Not Crank) 1622
E-2 Manual Preheating System Does Not Operate 1628
E-3 Automatic Preheating System Does Not Operate 1631
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1633
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1635
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1638
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1639
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1640
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1641
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1642
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1643
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1644
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1645
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1646
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1647
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1648
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1649
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1651
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1652
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1653
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1654
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1656
E-23 Some Areas of Machine Monitor Screen are Not Shown 1657
E-24 Function Switch Does Not Operate 1658
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1659
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1660
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1661
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1662
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1663
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1664
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1665
E-32 Alarm Buzzer Cannot be Canceled 1667
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1668
E-34 Service Mode Cannot be Selected 1669
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1670
E-36 All Work Equipment, Swing and Travel Do Not Lock 1673
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1675
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1678
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1680
E-40 One-Touch Power Maximizing Function is Not Cancelled 1683
E-41 Alarm Does Not Sound During Travel 1684
E-42 Alarm Does Not Stop When Machine Stops 1686
E-43 Horn Does Not Sound 1687
E-44 Horn Does Not Stop 1690
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1692
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1693
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1695
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1696
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1697
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1698
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1699
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1700
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1701
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1702
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1703
E-56 Service is Not Shown Correctly with Monitoring Function 1704
E-57 Attachment Hydraulic Circuit Cannot be Changed 1706
E-58 KOMTRAX System Does Not Operate Correctly 1707
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1708
Information Shown in Troubleshooting Table (H-Mode) 1708
Failure Mode and Cause Table 1709
H-1 All Work Equipment, Swing and Travel Do Not Work 1719
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1720
H-3 Fine Control Performance or Response is Unsatisfactory 1722
H-4 Unusual Noise is Heard from Around Hydraulic Pump 1723
H-5 Engine Speed Drops Largely or Engine Stops 1724
H-6 Speed or Power of Boom is Low 1726
H-7 Arm Speed or Power is Low 1729
H-8 Bucket Speed or Power is Low 1733
H-9 Work Equipment Does Not Move in Single Operation 1735
H-10 Hydraulic Drift of Boom is Large 1736
H-11 Hydraulic Drift of Arm is Large 1737
H-12 Hydraulic Drift of Bucket is Large 1739
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1740
H-14 Time Lag of Work Equipment is Large 1741
H-15 One-Touch Power Maximizing Function Does Not Operate 1742
H-16 Attachment Circuit Cannot be Changed 1743
H-17 Oil Flow in Attachment Circuit Cannot be Changed 1744
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1745
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 1746
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1747
H-21 Machine Does Not Travel Straight 1748
H-22 Machine is Not Steered Correctly or Steering Power is Low 1751
H-23 Travel Speed is Low 1753
H-24 One of Tracks Does Not Run 1755
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1756
H-26 Upper Structure Does Not Swing to Right and Left 1757
H-27 Upper Structure Swings Only to Right or Left 1758
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 1759
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 1760
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1761
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1762
H-32 Shock is Large When Upper Structure Stops Swing Operation 1763
H-33 There is Large Unusual Noise When It Stops Swing Operation 1764
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1765
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1766
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1767
H-37 Unusual Noise is Heard from Around Fan 1768
Troubleshooting of Engine (S-Mode) 1769
Information Shown in Troubleshooting Table (S-Mode) 1769
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1770
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1771
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1772
S-4 Engine Startability is Unsatisfactory 1774
S-5 Engine Does Not Pick Up Smoothly 1776
S-6 Engine Stops During Operation 1778
S-7 Engine Runs Rough or is Not Stable 1780
S-8 Engine Lacks Power 1781
S-9 Exhaust Smoke is Black 1783
S-10 Engine Oil Consumption is Excessive 1785
S-11 Oil Becomes Dirty Quickly 1786
S-12 Fuel Consumption is Excessive 1787
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1788
S-14 Oil Pressure Drops 1789
S-15 Fuel Mixes Into Engine Oil 1791
S-16 Water Mixes Into Engine Oil (Milky) 1792
S-17 Coolant Temperature Increases Too High (Overheating) 1793
S-18 Unusual Noise is Heard 1794
S-19 Vibration is Excessive 1795
S-20 Air Cannot be Bled from Fuel Circuit 1796
S-21 Active Regeneration is Done Frequently 1797
S-22 Active Regeneration Continues Long 1798
S-23 White Smoke is Exhausted During Active Regeneration 1799
S-24 DEF Consumption is Excessive 1800
S-25 There is Unusual Smell (Irritating Odor) 1802
S-26 Foreign Materials Enter DEF (DEF Increases) 1803
50 Disassembly and Assembly 1805
Table of Contents 1806
Precautions Before Work 1811
Related Information on Disassembly and Assembly 1812
How to Read This Manual 1812
Coating Materials List 1814
Special Tool List 1819
Sketches of Special Tools 1833
Engine and Cooling System 1841
Remove and Install Supply Pump Assembly 1841
How to Remove Supply Pump Assembly 1841
How to Install Supply Pump Assembly 1845
Remove and Install Injector Assembly 1849
How to Remove Injector Assembly 1849
How to Install Injector Assembly 1852
Remove and Install Cylinder Head Assembly 1858
How to Remove Cylinder Head Assembly 1858
How to Install Cylinder Head Assembly 1868
Remove and Install EGR Valve Assembly 1885
How to Remove EGR Valve Assembly 1885
How to Install EGR Valve Assembly 1886
Remove and Install EGR Cooler Assembly 1888
How to Remove EGR Cooler Assembly 1888
How to Install EGR Cooler Assembly 1890
Remove and Install Starter Assembly 1893
How to Remove Starting Motor Assembly 1893
How to Install Starting Motor Assembly 1895
Remove and Install Alternator Belt 1898
How to Remove Alternator Belt 1898
How to Install Alternator Belt 1900
Remove and Install Radiator Assembly 1903
How to Remove Radiator Assembly 1903
How to Install Radiator Assembly 1907
Remove and Install Hydraulic Oil Cooler Assembly 1911
How to Remove Hydraulic Oil Cooler Assembly 1911
How to Install Hydraulic Oil Cooler Assembly 1915
Remove and Install Aftercooler Assembly 1919
How to Remove Aftercooler Assembly 1919
How to Install Aftercooler Assembly 1921
Remove and Install Fan Clutch Assembly 1924
How to Remove Fan Clutch Assembly 1924
How to Install Fan Clutch Assembly 1928
Remove and Install Fan 1932
How to Remove Fan 1932
How to Install Fan 1932
Remove and Install Engine and Main Pump Assembly 1933
How to Remove Engine and Main Pump Assembly 1933
How to Install Engine and Main Pump Assembly 1949
Remove and Install Engine Front Oil Seal 1966
How to Remove Engine Front Oil Seal 1966
How to Install Engine Front Oil Seal 1970
Remove and Install Engine Rear Oil Seal 1976
How to Remove Engine Rear Oil Seal 1976
How to Install Engine Rear Oil Seal 1977
Remove and Install Fuel Cooler Assembly 1980
How to Remove Fuel Cooler Assembly 1980
How to Install Fuel Cooler Assembly 1982
Remove and Install Engine Hood Assembly 1985
How to Remove Engine Hood Assembly 1985
How to Install Engine Hood Assembly 1987
Remove and Install KDOC Assembly 1993
How to Remove KDOC Assembly 1993
How to Install KDOC Assembly 1996
Remove and Install KDOC and SCR Assembly 1999
How to Remove KDOC and SCR Assembly 1999
How to Install KDOC and SCR Assembly 2006
Remove and Install Bellows Pipe Assembly 2013
How to Remove Bellows Pipe Assembly 2013
How to Install Bellows Pipe Assembly 2015
Remove and Install Fuel Tank Assembly 2020
How to Remove Fuel Tank Assembly 2020
How to Install Fuel Tank Assembly 2025
Remove and Install DEF Tank Assembly 2031
How to Remove DEF Tank Assembly 2031
How to Install DEF Tank Assembly 2039
Remove and Install DEF Tank Sensor Flange Assembly 2045
How to Remove DEF Tank Sensor Flange Assembly 2045
How to Install DEF Tank Sensor Flange Assembly 2046
Remove and Install DEF Tank Sensor 2048
How to Remove DEF Tank Sensor 2048
How to Install DEF Tank Sensor 2049
Remove and Install DEF Tank Strainer 2051
How to Remove DEF Tank Strainer 2051
How to Install DEF Tank Strainer 2051
Remove and Install DEF Tank Filler Port Filter 2052
How to Remove DEF Tank Filler Port Filter 2052
How to Install DEF Tank Filler Port Filter 2054
Remove and Install SCR Assembly 2057
How to Remove SCR Assembly 2057
How to Install SCR Assembly 2059
Remove and Install KCCV Assembly 2061
How to Remove KCCV Assembly 2061
How to Install KCCV Assembly 2062
Remove and Install DEF Mixing Tube 2064
How to Remove DEF Mixing Tube 2064
How to Install DEF Mixing Tube 2071
Remove and Install DEF Injector 2077
How to Remove DEF Injector 2077
How to Install DEF Injector 2080
Remove and Install DEF Pump 2083
How to Remove DEF Pump 2083
How to Install DEF Pump 2086
Remove and Install DEF Hose 2089
How to Remove DEF Hose 2089
How to Install DEF Hose 2099
Remove and Install Air Cleaner Assembly 2109
How to Remove Air Cleaner Assembly 2109
How to Install Air Cleaner Assembly 2110
Remove and Install Air Conditioner Compressor Assembly 2113
How to Remove Air Conditioner Compressor Assembly 2113
How to Install Air Conditioner Compressor Assembly 2115
Remove and Install Air Conditioner Condenser Assembly 2118
How to Remove Air Conditioner Condenser Assembly 2118
How to Install Air Conditioner Condenser Assembly 2119
Power Train 2121
Remove and Install Travel Motor and Final Drive Assembly 2121
How to Remove Travel Motor and Final Drive Assembly 2121
How to Install Travel Motor and Final Drive Assembly 2122
Disassemble and Assemble Final Drive Assembly 2123
How to Disassemble Final Drive Assembly 2124
How to Assemble Final Drive Assembly 2127
Remove and Install Swing Motor and Swing Machinery Assembly 2135
How to Remove Swing Motor and Swing Machinery Assembly 2135
How to Install Swing Motor and Swing Machinery Assembly 2137
Disassemble and Assemble Swing Machinery Assembly 2139
How to Disassemble Swing Machinery Assembly 2139
How to Assemble Swing Machinery Assembly 2143
Remove and Install Swing Circle Assembly 2150
How to Remove Swing Circle Assembly 2150
How to Install Swing Circle Assembly 2150
Undercarriage and Frame 2152
Separate and Connect Track Assembly 2152
How to Separate Track Assembly 2152
How to Install Track Assembly 2153
Remove and Install Sprocket 2156
How to Remove Sprocket 2156
How to Install Sprocket 2157
Remove and Install Idler and Idler Cushion Assembly 2158
How to Remove Idler and Idler Cushion Assembly 2158
How to Install Idler and Idler Cushion Assembly 2159
Disassemble and Assemble Idler Assembly 2160
How to Disassemble Idler Assembly 2160
How to Assemble Idler Assembly 2161
Disassemble and Assemble Idler Cushion Assembly 2165
How to Disassemble Idler Cushion Assembly 2165
How to Assemble Idler Cushion Assembly 2166
Disassemble and Assemble Track Roller Assembly 2168
How to Disassemble Track Roller Assembly 2168
How to Assemble Track Roller Assembly 2169
Disassemble and Assemble Carrier Roller Assembly 2172
How to Disassemble Carrier Roller Assembly 2172
How to Assemble Carrier Roller Assembly 2174
Remove and Install Revolving Frame Assembly 2176
How to Remove Revolving Frame Assembly 2176
How to Install Revolving Frame Assembly 2179
Remove and Install Counterweight Assembly 2182
How to Remove Counterweight Assembly 2182
How to Install Counterweight Assembly 2183
Hydraulic System 2186
Remove and Install Center Swivel Joint Assembly 2186
How to Remove Center Swivel Joint Assembly 2186
How to Install Center Swivel Joint Assembly 2189
Disassemble and Assemble Center Swivel Joint Assembly 2192
How to Disassemble Center Swivel Joint Assembly 2192
How to Assemble Center Swivel Joint Assembly 2193
Remove and Install Hydraulic Tank Assembly 2195
How to Remove Hydraulic Tank Assembly 2195
How to Install Hydraulic Tank Assembly 2202
Remove and Install Main Pump Assembly 2210
How to Remove Main Pump Assembly 2210
How to Install Main Pump Assembly 2212
Remove and Install Control Valve Assembly 2215
How to Remove Control Valve Assembly 2215
How to Install Control Valve Assembly 2218
Disassemble and Assemble Control Valve Assembly 2222
How to Assemble Control Valve Assembly 2222
How to Replace Pressure Reducing Valve Cartridge Assembly 2224
Disassemble and Assemble Work Equipment PPC Valve Assembly 2227
How to Disassemble Work Equipment PPC Valve Assembly 2227
How to Assemble Work Equipment PPC Valve Assembly 2228
Work Equipment 2230
Remove and Install Work Equipment Assembly 2230
How to Remove Work Equipment Assembly 2230
How to Install Work Equipment Assembly 2233
Remove and Install Boom Anti-drop Valve Assembly 2237
How to Remove Boom Anti-drop Valve Assembly 2237
How to Install Boom Anti-drop Valve Assembly 2239
Remove and Install Arm Anti-Drop Valve Assembly 2240
How to Remove Arm Anti-Drop Valve Assembly 2240
How to Install Arm Anti-Drop Valve Assembly 2242
Disassemble and Assemble Anti-Drop Valve Assembly 2243
How to Disassemble Anti-Drop Valve Assembly 2243
How to Assemble Anti-Drop Valve Assembly 2243
Disassemble and Assemble Work Equipment Cylinder Assembly 2244
How to Disassemble Work Equipment Cylinder Assembly 2245
How to Assemble Work Equipment Cylinder Assembly 2247
CAB Related Parts 2253
Remove and Install Operator Cab Assembly 2253
How to Remove Operator Cab Assembly 2253
How to Install Operator Cab Assembly 2260
Remove and Install Operator Cab Glass (Adhered Glass) 2268
How to Remove Operator Cab Glass (Adhered Glass) 2270
How to Install Operator Cab Glass (Adhered Glass) 2270
Remove and Install Front Window Assembly 2280
How to Remove Front Window Assembly 2280
How to Install Front Window Assembly 2283
Remove and Install Floor Frame Assembly 2289
How to Remove Floor Frame Assembly 2289
How to Install Floor Frame Assembly 2293
Remove and Install Air Conditioner Unit Assembly 2298
How to Remove Air Conditioner Unit Assembly 2298
How to Install Air Conditioner Unit Assembly 2302
Remove and Install Operator Seat 2308
How to Remove Operator Seat 2308
How to Install Operator Seat 2310
How to Remove and Install Seat Belt 2313
How to Remove Seat Belt 2313
How to Install Seatbelt 2313
Remove and Install Work Equipment Control Lever Assembly 2315
How to Remove Work Equipment Control Lever Assembly 2315
How to Install Work Equipment Control Lever Assembly 2321
Remove and Install Front Wiper Assembly 2330
How to Remove Front Wiper Assembly 2330
How to Install Front Wiper Assembly 2335
Electrical System 2344
Remove and Install Engine Controller Assembly 2344
How to Remove Engine Controller Assembly 2344
How to Install Engine Controller Assembly 2346
Remove and Install Pump Controller Assembly 2349
How to Remove Pump Controller Assembly 2349
How to Install Pump Controller Assembly 2352
Remove and Install Machine Monitor Assembly 2355
How to Remove Machine Monitor Assembly 2355
How to Install Machine Monitor Assembly 2357
Remove and Install Pump Swash Plate Sensor 2361
How to Remove Pump Swash Plate Sensor 2361
How to Install Pump Swash Plate Sensor 2361
Remove and Install Mass Air Flow and Temperature Sensor 2363
How to Remove Mass Air Flow and Temperature Sensor 2363
How to Install Mass Air Flow and Temperature Sensor 2364
Remove and Install KCCV Crankcase Pressure Sensor 2366
How to Remove KCCV Crankcase Pressure Sensor 2366
How to Install KCCV Crankcase Pressure Sensor 2367
Remove and Install SCR Temperature Sensor 2369
How to Remove SCR Temperature Sensor 2369
How to Install SCR Temperature Sensor 2370
Remove and Install KOMTRAX Terminal Assembly 2372
How to Remove KOMTRAX Terminal Assembly 2372
How to Install KOMTRAX Terminal Assembly 2374
60 Maintenance Standard 2377
Table of Contents 2378
Engine and Cooling System 2379
Maintenance Standard for Engine Mount 2379
Maintenance Standard for Cooling System 2380
Power Train 2382
Maintenance Standard for Swing Circle 2382
Maintenance Standard for Swing Machinery 2383
Maintenance Standard for Final Drive 2385
Maintenance Standard for Sprocket 2387
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2388
Undercarriage and Frame 2389
Maintenance Standard for Track Frame and Idler Cushion 2389
Maintenance Standard for Idler 2391
Maintenance Standard for Track Roller 2393
Maintenance Standard for Carrier Roller 2394
Maintenance Standard for Track Shoes 2395
Maintenance Standard for Triple Shoes 2398
Hydraulic System 2399
Maintenance Standard for Hydraulic Tank 2399
Maintenance Standard for Main Pump 2400
Maintenance Standard for PC-EPC Valve 2402
Maintenance Standard for Travel Motor 2403
Maintenance Standard for Control Valve 2406
Maintenance Standard for Boom Anti-Drop Valve 2417
Maintenance Standard for Arm Anti-Drop Valve 2419
Maintenance Standard for Work Equipment and Swing PPC Valve 2421
Maintenance Standard for Travel PPC Valve 2424
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2427
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2428
Maintenance Standard for 2nd-Line Attachment PPC Valve 2430
Maintenance Standard for Solenoid Valve 2432
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2433
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2434
Maintenance Standard for Center Swivel Joint 2435
Work Equipment 2436
Maintenance Standard for Work Equipment Linkage 2436
Dimensions of Arm 2441
Dimensions of Bucket 2443
Maintenance Standard for Boom Cylinder 2445
Maintenance Standard for Arm Cylinder 2446
Maintenance Standard for Bucket Cylinder 2447
80 Appendix 2449
Table of Contents 2450
Precautions Before Work 2452
Air Conditioner System 2453
Precautions for Refrigerant 2453
Air Conditioner Component 2454
Specifications of Air Conditioner 2456
Structure and Function of Refrigeration Cycle 2457
Outline of Refrigeration Cycle 2458
Component Parts of Air Conditioner System 2460
Air Conditioner Unit 2460
Configuration Diagram of Air Conditioner Unit 2460
Function of Air Conditioner Unit 2462
Component Parts of Air Conditioner Unit 2464
Function of Evaporator as Air Conditioner Unit Component 2465
Function of Heater Core as Air Conditioner Unit Component 2465
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2465
Function of Servo Motor as Air Conditioner Unit Component 2465
Structure of Expansion Valve as Air Conditioner Unit Component 2466
Function of Expansion Valve as Air Conditioner Unit Component 2466
Operate Expansion Valve as Air Conditioner Unit Component 2466
Function of Dual Pressure Switch 2467
Air Conditioner Controller 2468
Structure of Air Conditioner Controller 2468
Compressor 2469
Structure of Compressor 2469
Specifications of Compressor 2469
Function of Compressor 2469
Condenser 2470
Structure of Condenser 2470
Specifications of Condenser 2470
Function of Condenser 2470
Air Conditioner Related Sensors 2472
Structure of Sunlight Sensor 2472
Function of Sunlight Sensor 2472
Structure of Outside Temperature Sensor 2472
Function of Outside Air Temperature Sensor 2472
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2474
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2476
System Diagram of Air Conditioner 2478
Input and Output Signals of Air Conditioner Controller 2479
Function of Air Conditioner Controller 2480
Locations of Air Conditioner Parts and Layout of Connectors 2481
Examine Air Leakage (Duct) 2485
How to Examine Air Leakage (Duct) 2485
Examine Air Conditioner with Self-Diagnosis Function 2487
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2488
Examine Vent (Mode) Changeover 2489
How to Examine Vent (Mode) Changeover 2489
Examine Fresh/Recirc Air Changeover 2491
How to Examine Fresh/Recirc Air Changeover 2491
Examine Sunlight Sensor 2492
How to Examine Sunlight Sensor 2492
Examine Refrigerant (Dual) Pressure Switch 2493
How to Examine Refrigerant (Dual) Pressure Switch 2493
Examine Relay 2494
How to Examine Relay 2494
Air Conditioner Troubleshooting Chart 1 2495
Air Conditioner Troubleshooting Chart 2 2496
Information Shown in Troubleshooting Table 2499
Failure Code [879AKA] 2500
Failure Code [879AKB] 2501
Failure Code [879BKA] 2502
Failure Code [879BKB] 2504
Failure Code [879CKA] 2506
Failure Code [879CKB] 2507
Failure Code [879DKZ] 2508
Failure Code [879EMC] 2510
Failure Code [879FMC] 2511
Failure Code [879GKX] 2512
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2514
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2516
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2519
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2521
Troubleshooting by Gauge Pressure 2523
Connect Service Tool 2526
How to Connect Service Tool 2526
Precautions for Disconnection and Connection of Air Conditioner Piping 2528
Handle Compressor Oil 2530
How to Replace Desiccant 2532
90 Circuit Diagrams 2535
Table of Contents 2536
Hydraulic Circuit Diagram 2537
Symbols Used in Hydraulic Circuit Diagram 2537
Hydraulic Circuit Diagram 2541
Electrical Circuit Diagram 2543
Symbols Used in Electric Circuit Diagram 2543
Electrical Circuit Diagram (1/6) 2547
Electrical Circuit Diagram (2/6) 2549
Electrical Circuit Diagram (3/6) 2551
Electrical Circuit Diagram (4/6) 2553
Electrical Circuit Diagram (5/6) 2555
Electrical Circuit Diagram (6/6) 2557
Electrical Circuit Diagram (1/8) 2559
Electrical Circuit Diagram (2/8) 2561
Electrical Circuit Diagram (3/8) 2563
Electrical Circuit Diagram (4/8) 2565
Electrical Circuit Diagram (5/8) 2567
Electrical Circuit Diagram (6/8) 2569
Electrical Circuit Diagram (7/8) 2571
Electrical Circuit Diagram (8/8) 2573
Index 2575

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24