Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06735-08 PDF

Description

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06735-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06735-08 – PDF DOWNLOAD 

Language : English
Pages : 2674
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06735-08 – PDF DOWNLOAD 

SERIAL NUMBERS 35001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.

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 SEN06735-08 – 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
Precautions When You Handle Hydraulic Equipment 39
Precautions When You Disconnect and Connect Pipings 42
Precautions When You Handle Electrical Equipment 49
Precautions When You Handle Fuel System Equipment 51
Precautions When You Handle Intake System Equipment 52
Practical Use of KOMTRAX 53
Disconnect and Connect Push-Pull Type Coupler 54
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 56
Precautions for Disconnection and Connection of Connectors 58
How to Disconnect and Connect Deutsch Connector 62
How to Disconnect and Connect Slide Lock Type Connector 63
How to Disconnect and Connect Connector with Lock to Pull 65
How to Disconnect and Connect Connector with Lock to Push 66
How to Disconnect and Connect Connector with Housing to Rotate 68
How to Read the Codes for Electric Cable 69
Explanation of Terms for Maintenance Standard 73
Standard Tightening Torque Table 76
Conversion Table 83
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
Operation of System Operating 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
Operation 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
Operation 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 187
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
Gateway Function Controller 213
Communication Terminal 216
Pump Controller 218
Resistor for PC-EPC Valve 222
CAN Terminating Resistor 223
Engine Controller 224
Fuel Control Dial 231
Hydraulic System 233
Layout Drawing of Hydraulic System 233
CLSS 237
Structure of CLSS 237
Function of CLSS 238
Engine and Pump Combined Control System 240
Engine and Pump Combined Control System Diagram 240
Function of Engine and Pump Combined Control System 241
Pump and Valve Control System 246
Pump and Valve Control System Diagram 246
Function of Pump and Valve Control System 247
Component Parts of Hydraulic System 249
Hydraulic Tank 249
Main Pump 251
Control Valve 274
Work Equipment System 337
Layout Drawing of Work Equipment System 337
One-Touch Power Maximizing System 341
System Diagram of One-Touch Power Maximizing System 341
Function of One-Touch Power Maximizing System 341
PPC Lock System 343
System Diagram of PPC Lock 343
Function of PPC Lock System 343
Work Equipment and Travel Automatic Lock System 344
System Diagram of Lock Lever Automatic Lock System 344
Function of Work Equipment and Travel Automatic Lock System 344
Operation of Lock Lever Automatic Lock System 345
Attachment Oil Flow Adjuster System 346
Attachment Oil Flow Adjuster System Diagram 346
Function of Attachment Oil Flow Adjuster System 347
Component Parts of Work Equipment System 348
Work Equipment and Swing PPC Valve 348
1st-Line Attachment PPC Valve (with EPC Valve) 354
2nd-Line Attachment PPC Valve 363
Solenoid Valve 365
Boom Anti-drop Valve 367
Arm Anti-Drop Valve 371
Attachment Circuit Selector Valve (For High Pressure) 376
Attachment Circuit Selector Valve (For Low Pressure) 378
Pilot Circuit Accumulator 380
Attachment Circuit Accumulator 381
Swing System 382
Layout Drawing of Swing System 382
Swing Control System Diagram 386
Function of Swing Control System 386
Component Parts of Swing System 389
Swing Motor 389
Swing Machinery 393
Swing Circle 395
Travel System 397
Layout Drawing of Travel System 397
System Diagram of Travel Control System 400
Function of Travel Control System 401
Component Parts of Travel System 402
Travel Motor 402
Final Drive 414
Travel PPC Valve 416
Center Swivel Joint 420
Undercarriage and Frame 422
Layout Drawing of Undercarriage 422
Specifications of Undercarriage 423
Work Equipment 424
Structure of Work Equipment 424
Function of Work Equipment 425
Work Equipment Clearance Adjustment Shim 426
Function of Work Equipment Clearance Adjustment Shim 426
Bucket Clearance Adjustment Shim 427
Function of Bucket Clearance Adjustment Shim 427
CAB Related Parts 428
ROPS CAB 428
Structure of ROPS CAB 428
Function of ROPS CAB 428
CAB Mount 429
Structure of CAB Mount 429
Function of CAB Mount 429
CAB Tipping Stopper 430
Structure of CAB Tipping Stopper 430
Function of CAB Tipping Stopper 430
20 Standard Value Table 431
Table of Contents 432
Standard Value Table for Engine 433
Standard Value Table for Engine: PC170LC-11 433
Standard Value Table for Machine 437
Standard Value Table for Machine: PC170LC-11 437
Machine Posture and Procedures to Measure Performance 450
30 Testing and Adjusting 455
Table of Contents 456
Precautions Before Work 459
Related Information on Testing and Adjusting 460
Tools for Testing and Adjusting 460
Sketch of Tools for Testing and Adjusting 467
Engine and Cooling System 469
Examine Engine Speed 469
How to Examine Engine Speed 469
Examine Boost Pressure 471
How to Examine Boost Pressure on Machine Monitor 471
How to Examine Boost Pressure by Testing Tool 472
Examine Exhaust Gas Color 473
How to Examine Exhaust Gas Color with the Handy Smoke Checker 473
How to Examine Exhaust Gas Color with Smoke Meter 474
Examine and Adjust Valve Clearance 475
How to Examine Valve Clearance 475
How to Adjust Valve Clearance 476
Examine Compression Pressure 478
How to Examine Compression Pressure 478
Examine Blowby Pressure 483
How to Examine Blowby Pressure 483
Examine Engine Oil Pressure 485
How to Examine Engine Oil Pressure 485
Examine Fuel Pressure 486
How to Examine Fuel Pressure 487
Examine Fuel Discharge, Return and Leakage 491
How to Examine Fuel Discharge, Return, and Leakage 492
Bleed Air from Fuel System 496
How to Bleed Air from Fuel System 496
Examine Fuel Circuit for Leakage 497
How to Examine Fuel System for Leakage 497
Handle Cylinder Cut-out Mode Operation 499
Handle No-Injection Cranking Operation 500
Examine and Adjust Air Conditioner Compressor Belt Tension 501
How to Examine Air Conditioner Compressor Belt 501
How to Adjust Air Conditioner Compressor Belt 501
Examine Fan Belt and Alternator Belt 503
How to Examine Fan Belt and Alternator Belt 503
Examine Automatic Tensioner 504
How to Examine Automatic Tensioner 504
Examine Cooling Fan Speed 505
How to Examine Cooling Fan Speed 505
Examine SCR Related Functions 506
Examine DEF Pump Raised Pressure 509
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 520
Examine DEF Tank Heater Valve 524
Examine SCR Denitration Efficiency 526
Clean DEF Tank 530
How to Clean DEF Tank 530
Clean DEF Pump 534
How to Clean DEF Pump 534
Bleed Air from Coolant Circuit of DEF Tank 541
How to Bleed Air from Coolant Circuit of DEF Tank 541
Power Train 543
Examine Swing Circle Bearing Clearance 543
How to Examine Swing Circle Bearing Clearance 543
Undercarriage and Frame 544
Examine and Adjust Track Tension 544
How to Examine Track Tension 544
How to Adjust Track Tension 544
Hydraulic System 546
Release Remained Pressure in Hydraulic Circuit 546
How to Release Remained Pressure from Hydraulic Tank 546
How to Release Remained Pressure in Hydraulic Cylinder Circuit 546
How to Release Remained Pressure from Swing Motor Circuit 548
How to Release Remained Pressure from Travel Motor Circuit 548
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 549
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 549
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 555
Examine Oil Pressure of Control Circuit 557
How to Examine Oil Pressure in Control Circuit 557
Examine and adjust oil pressure in pump PC control circuit 559
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 559
How to Examine PC-EPC Valve Outlet Pressure 560
How to Adjust Oil Pressure in Pump PC Control Circuit 561
Examine and Adjust Oil Pressure in Pump LS Control Circuit 563
How to Examine LS Differential Pressure with Machine Monitor 563
How to Examine LS Differential Pressure by Testing Tool 565
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 567
How to Adjust LS Valve 568
Examine Outlet Pressure of Solenoid Valve 569
How to Examine Outlet Pressure of Solenoid Valve 569
Operating Condition of Solenoid Valve 570
Examine PPC Valve Outlet Pressure 573
How to Examine Outlet Pressure in PPC Valve 573
Adjust Play of Work Equipment and Swing PPC Valves 575
How to Adjust Play of Work Equipment and Swing PPC Valves 575
Examine Pump Swash Plate Sensor 576
How to Examine pump swash plate sensor 576
Examine and Adjust Travel Deviation 577
How to Examine Travel Deviation 577
How to Adjust Travel Deviation 577
Examine Parts Which Cause Hydraulic Drift of Work Equipment 580
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 580
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 580
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 581
Examine Oil Leakage 582
How to Examine Oil Leakage from Boom Cylinder 582
How to Examine Oil Leakage from Arm Cylinder 582
How to Examine Oil Leakage from Bucket Cylinder 583
How to Examine Oil Leakage from Swing Motor 584
How to Examine Oil Leakage from Travel Motor 584
Bleed Air from Hydraulic System 585
How to Bleed Air from Hydraulic System 586
CAB Related Parts 589
Examine CAB Tipping Stopper 589
How to Examine Cab Tipping Stopper 589
How to Adjust Mirrors 590
Procedure to Adjust Machine Left Front Mirror (A) 590
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 591
Procedure to Adjust Machine Right Front Mirror (B) 592
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 593
Procedure to Adjust Machine Right Side Mirror (C) 595
Electrical System 596
Set and Operate Machine Monitor 596
Operator Mode 599
Function to Show Technician Identification Status Screen 599
Function to Show Operator Identification Input Screen 600
Examine Function by LCD (Liquid Crystal Display) 600
Examine Function of Service Meter 601
Usage Limitation and Maintenance Password Change Function 601
Service Mode 603
How to Operate Service Mode 603
How to See Pre-defined Monitoring Information 605
How to Examine Self-Define Monitor Information 612
Abnormality Record Menu 622
How to See Maintenance Record 626
Maintenance Mode Setting 627
How to Set Phone Number Entry 631
Default Menu 632
Diagnostic Tests Menu 640
Adjustment Menu 647
No-Injection Cranking Operation 665
KOMTRAX Settings Menu 666
How to Show Service Message 668
How to Start Up KOMTRAX System 670
Adjust Rearview Camera Angle 675
How to Adjust Rearview Camera Angle 675
Adjust KomVision Camera Angle 678
How to Adjust KomVision Camera Angle 679
Adjust KomVision Related Function 683
Setting of KomVision (Main Setting) 683
Setting of KomVision (Camera Setting) 685
Setting of KomVision (Camera Calibration) 687
KomVision screen – Check 12 m visibility 700
Handle Voltage Circuit of Engine Controller 703
Handle Battery Disconnect Switch 704
Examine Diodes 705
How to Examine Diodes by Digital Tester 705
How to Examine Diodes by Analog Tester 705
Pm Clinic 706
Pm Clinic Service 706
Pm Clinic Check Sheet: PC170LC-11 707
40 Troubleshooting 717
Table of Contents 718
Precautions Before Work 728
Related Information to Troubleshooting 729
General Troubleshooting Points 729
Troubleshooting Points for Urea SCR System 730
Sequence of Events in Troubleshooting 744
Checks Before Troubleshooting 746
Inspection Procedure Before Troubleshooting 748
Walk-Around Check 748
Test in Accordance with Testing Procedure 750
Examine Fuel Level and Type 750
Examine for Impure Ingredient in Fuel 750
Examine Fuel Prefilter 751
Examine Water Separator, Drain Water and Sediment 751
How to Replace Fuel Prefilter Cartridge 752
Examine Fuel Main Filter 754
Examine Engine Oil Level (Oil Quantity in Oil Pan) 755
Examine Coolant Level (Reservoir Tank) 756
Examine Air Cleaner Clogging 757
Clean Outer Element 757
Replace Element 760
Examine Hydraulic Oil Level 762
Examine Hydraulic Oil Strainer 763
Examine Hydraulic Oil Filter 764
Examine Oil Level in Swing Machinery Case 765
Examine Oil Level in Damper Case 766
Examine Oil Level in Final Drive Case 766
Bleed Air from Fuel System 767
Bleed Air from Hydraulic System 767
How to Examine Electric Equipment 767
Preparation for Troubleshooting of Electrical System 773
Preparation for Troubleshooting of Machine Monitor 773
Preparation for Troubleshooting of Engine Controller 773
Preparation for Troubleshooting of Pump Controller 773
Preparation for Troubleshooting of KomVision Controller 773
Preparation for Troubleshooting of Gateway Function Controller 774
How to Disconnect and Connect Connector with a Special Lock 777
Procedure for Troubleshooting 781
Symptom and Troubleshooting Numbers 784
Information Shown in Troubleshooting Table 788
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 790
Connector List and Layout 793
Connector Contact Connection Table 806
T-Branch Box and T-Branch Adapter Table 846
Fuse Location Table 852
Precautions When You Replace KDOC 855
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 856
Failure Code Table 858
Troubleshooting by Failure Code (Display of Code) 875
Failure Code [879AKA] 875
Failure Code [879AKB] 876
Failure Code [879BKA] 877
Failure Code [879BKB] 879
Failure Code [879CKA] 881
Failure Code [879CKB] 882
Failure Code [879DKZ] 883
Failure Code [879EMC] 885
Failure Code [879FMC] 886
Failure Code [879GKX] 887
Failure Code [989L00] 889
Failure Code [989M00] 890
Failure Code [989N00] 891
Failure Code [A1U0N3] 892
Failure Code [A1U0N4] 894
Failure Code [A900FR] 896
Failure Code [A900N6] 897
Failure Code [A900NY] 898
Failure Code [AA10NX] 899
Failure Code [AB00KE] 901
Failure Code [AQ10MB] 904
Failure Code [AQ10N3] 906
Failure Code [AS00N3] 908
Failure Code [AS00R2] 910
Failure Code [AS00R3] 911
Failure Code [AS00R4] 912
Failure Code [AS00R5] 913
Failure Code [AS00R6] 914
Failure Code [AS00ZK] 915
Failure Code [AS10KM] 916
Failure Code [AS10NR] 917
Failure Code [AS10NT] 919
Failure Code [B@BAZG] 920
Failure Code [B@BAZK] 921
Failure Code [B@BCNS] 923
Failure Code [B@BCZK] 924
Failure Code [B@HANS] 926
Failure Code [CA115] 927
Failure Code [CA122] 928
Failure Code [CA123] 930
Failure Code [CA131] 932
Failure Code [CA132] 934
Failure Code [CA144] 936
Failure Code [CA145] 938
Failure Code [CA153] 940
Failure Code [CA154] 943
Failure Code [CA187] 946
Failure Code [CA221] 948
Failure Code [CA222] 950
Failure Code [CA227] 952
Failure Code [CA234] 954
Failure Code [CA238] 955
Failure Code [CA239] 956
Failure Code [CA249] 957
Failure Code [CA256] 959
Failure Code [CA271] 961
Failure Code [CA272] 963
Failure Code [CA295] 965
Failure Code [CA322] 966
Failure Code [CA324] 968
Failure Code [CA331] 970
Failure Code [CA332] 972
Failure Code [CA343] 974
Failure Code [CA351] 975
Failure Code [CA352] 977
Failure Code [CA356] 979
Failure Code [CA357] 981
Failure Code [CA386] 983
Failure Code [CA428] 984
Failure Code [CA429] 986
Failure Code [CA435] 988
Failure Code [CA441] 990
Failure Code [CA442] 992
Failure Code [CA451] 994
Failure Code [CA452] 996
Failure Code [CA488] 998
Failure Code [CA515] 999
Failure Code [CA516] 1001
Failure Code [CA553] 1003
Failure Code [CA555] 1004
Failure Code [CA556] 1005
Failure Code [CA559] 1006
Failure Code [CA595] 1009
Failure Code [CA687] 1011
Failure Code [CA689] 1013
Failure Code [CA691] 1015
Failure Code [CA692] 1017
Failure Code [CA697] 1019
Failure Code [CA698] 1020
Failure Code [CA731] 1021
Failure Code [CA778] 1023
Failure Code [CA1117] 1028
Failure Code [CA1664] 1030
Failure Code [CA1669] 1032
Failure Code [CA1673] 1033
Failure Code [CA1677] 1034
Failure Code [CA1678] 1035
Failure Code [CA1682] 1036
Failure Code [CA1683] 1038
Failure Code [CA1684] 1040
Failure Code [CA1686] 1042
Failure Code [CA1691] 1043
Failure Code [CA1694] 1045
Failure Code [CA1695] 1047
Failure Code [CA1696] 1048
Failure Code [CA1712] 1050
Failure Code [CA1713] 1053
Failure Code [CA1714] 1055
Failure Code [CA1715] 1056
Failure Code [CA1776] 1057
Failure Code [CA1777] 1059
Failure Code [CA1843] 1062
Failure Code [CA1844] 1064
Failure Code [CA1885] 1066
Failure Code [CA1887] 1068
Failure Code [CA1896] 1070
Failure Code [CA1898] 1071
Failure Code [CA1938] 1073
Failure Code [CA1942] 1075
Failure Code [CA1961] 1076
Failure Code [CA1962] 1077
Failure Code [CA2185] 1078
Failure Code [CA2186] 1079
Failure Code [CA2198] 1081
Failure Code [CA2249] 1083
Failure Code [CA2272] 1084
Failure Code [CA2288] 1086
Failure Code [CA2311] 1087
Failure Code [CA2349] 1088
Failure Code [CA2353] 1090
Failure Code [CA2357] 1092
Failure Code [CA2373] 1093
Failure Code [CA2374] 1095
Failure Code [CA2375] 1097
Failure Code [CA2376] 1099
Failure Code [CA2387] 1102
Failure Code [CA2554] 1103
Failure Code [CA2634] 1105
Failure Code [CA2635] 1107
Failure Code [CA2636] 1108
Failure Code [CA2637] 1110
Failure Code [CA2771] 1112
Failure Code [CA2961] 1116
Failure Code [CA2973] 1117
Failure Code [CA2976] 1118
Failure Code [CA3142] 1120
Failure Code [CA3143] 1121
Failure Code [CA3144] 1122
Failure Code [CA3146] 1124
Failure Code [CA3147] 1125
Failure Code [CA3148] 1126
Failure Code [CA3151] 1128
Failure Code [CA3165] 1133
Failure Code [CA3228] 1135
Failure Code [CA3229] 1138
Failure Code [CA3231] 1140
Failure Code [CA3232] 1142
Failure Code [CA3235] 1146
Failure Code [CA3239] 1148
Failure Code [CA3241] 1151
Failure Code [CA3242] 1154
Failure Code [CA3251] 1157
Failure Code [CA3313] 1159
Failure Code [CA3314] 1160
Failure Code [CA3315] 1161
Failure Code [CA3419] 1163
Failure Code [CA3421] 1165
Failure Code [CA3497] 1167
Failure Code [CA3498] 1168
Failure Code [CA3545] 1169
Failure Code [CA3547] 1171
Failure Code [CA3558] 1172
Failure Code [CA3559] 1174
Failure Code [CA3562] 1176
Failure Code [CA3563] 1178
Failure Code [CA3567] 1181
Failure Code [CA3568] 1184
Failure Code [CA3571] 1188
Failure Code [CA3572] 1190
Failure Code [CA3574] 1192
Failure Code [CA3575] 1194
Failure Code [CA3577] 1196
Failure Code [CA3578] 1198
Failure Code [CA3582] 1200
Failure Code [CA3583] 1206
Failure Code [CA3596] 1208
Failure Code [CA3649] 1211
Failure Code [CA3681] 1213
Failure Code [CA3682] 1217
Failure Code [CA3713] 1221
Failure Code [CA3717] 1224
Failure Code [CA3718] 1225
Failure Code [CA3724] 1226
Failure Code [CA3725] 1227
Failure Code [CA3741] 1230
Failure Code [CA3748] 1231
Failure Code [CA3755] 1234
Failure Code [CA3866] 1236
Failure Code [CA3868] 1239
Failure Code [CA4152] 1242
Failure Code [CA4155] 1246
Failure Code [CA4156] 1248
Failure Code [CA4157] 1251
Failure Code [CA4159] 1253
Failure Code [CA4164] 1254
Failure Code [CA4165] 1256
Failure Code [CA4166] 1258
Failure Code [CA4168] 1259
Failure Code [CA4169] 1262
Failure Code [CA4171] 1264
Failure Code [CA4249] 1267
Failure Code [CA4251] 1269
Failure Code [CA4261] 1272
Failure Code [CA4277] 1275
Failure Code [CA4459] 1279
Failure Code [CA4461] 1281
Failure Code [CA4533] 1284
Failure Code [CA4534] 1285
Failure Code [CA4731] 1286
Failure Code [CA4732] 1287
Failure Code [CA4739] 1288
Failure Code [CA4768] 1289
Failure Code [CA4769] 1291
Failure Code [CA4842] 1293
Failure Code [CA4952] 1296
Failure Code [CA5115] 1298
Failure Code [CA5179] 1301
Failure Code [CA5181] 1303
Failure Code [CA5387] 1305
Failure Code [CA5388] 1307
Failure Code [CA5389] 1310
Failure Code [CA5391] 1312
Failure Code [CA5392] 1316
Failure Code [CA5393] 1318
Failure Code [CA5394] 1320
Failure Code [CA5395] 1322
Failure Code [CA5396] 1325
Failure Code [CA5631] 1326
Failure Code [CA5632] 1328
Failure Code [CA5938] 1329
Failure Code [D110KB] 1331
Failure Code [D19JKZ] 1333
Failure Code [D811MC] 1336
Failure Code [D862KA] 1337
Failure Code [D8ALKA] 1339
Failure Code [D8ALKB] 1342
Failure Code [D8AQKR] 1344
Failure Code [D8G1KT] 1351
Failure Code [D8G6KT] 1352
Failure Code [DA20MC] 1353
Failure Code [DA22KK] 1354
Failure Code [DA25KP] 1357
Failure Code [DA29KQ] 1360
Failure Code [DA2LKA] 1362
Failure Code [DA2LKB] 1365
Failure Code [DA2QKR] 1367
Failure Code [DA2RKR] 1376
Failure Code [DAF0KM] 1381
Failure Code [DAF0MB] 1382
Failure Code [DAF0MC] 1383
Failure Code [DAF8KB] 1384
Failure Code [DAF9KQ] 1386
Failure Code [DAFGMC] 1387
Failure Code [DAFLKA] 1388
Failure Code [DAFLKB] 1391
Failure Code [DAFQKR] 1393
Failure Code [DAZ9KQ] 1401
Failure Code [DAZQKR] 1402
Failure Code [DB2QKR] 1409
Failure Code [DB2RKR] 1417
Failure Code [DBP0KM] 1422
Failure Code [DBP0KT] 1423
Failure Code [DBP5KB] 1424
Failure Code [DBP5KY] 1427
Failure Code [DBPQKR] 1430
Failure Code [DDNRKA] 1438
Failure Code [DDNRKY] 1440
Failure Code [DDNS00] 1442
Failure Code [DFB1KZ] 1444
Failure Code [DFB2KZ] 1446
Failure Code [DFB3L8] 1448
Failure Code [DFB4L8] 1450
Failure Code [DFB5KZ] 1452
Failure Code [DFB6KZ] 1454
Failure Code [DGH2KA] 1456
Failure Code [DGH2KB] 1458
Failure Code [DHA4KA] 1460
Failure Code [DHPAMA] 1462
Failure Code [DHPBMA] 1465
Failure Code [DHS3MA] 1468
Failure Code [DHS4MA] 1471
Failure Code [DHS5MA] 1474
Failure Code [DHS8MA] 1476
Failure Code [DHS9MA] 1479
Failure Code [DHSAMA] 1482
Failure Code [DHSBMA] 1485
Failure Code [DHSCMA] 1488
Failure Code [DHSDMA] 1491
Failure Code [DKR0MA] 1494
Failure Code [DKULKA] 1497
Failure Code [DKULKB] 1499
Failure Code [DKULKY] 1501
Failure Code [DLM5KA] 1503
Failure Code [DLM5MB] 1506
Failure Code [DR10KA] 1508
Failure Code [DR12KA] 1511
Failure Code [DR20KA] 1513
Failure Code [DR21KX] 1515
Failure Code [DR30KA] 1517
Failure Code [DR31KX] 1519
Failure Code [DR40KA] 1521
Failure Code [DUMBKA] 1523
Failure Code [DUMBKB] 1526
Failure Code [DV20KB] 1528
Failure Code [DW43KA] 1530
Failure Code [DW43KB] 1532
Failure Code [DW43KY] 1534
Failure Code [DW45KA] 1536
Failure Code [DW45KB] 1539
Failure Code [DW45KY] 1542
Failure Code [DW4CKY] 1544
Failure Code [DW91KA] 1546
Failure Code [DW91KB] 1548
Failure Code [DW91KY] 1550
Failure Code [DWA2KA] 1552
Failure Code [DWA2KB] 1554
Failure Code [DWA2KY] 1556
Failure Code [DWJ0KA] 1558
Failure Code [DWJ0KB] 1560
Failure Code [DWJ0KY] 1562
Failure Code [DWK0KA] 1564
Failure Code [DWK0KB] 1566
Failure Code [DWK0KY] 1568
Failure Code [DWK2KA] 1570
Failure Code [DWK2KB] 1572
Failure Code [DWK2KY] 1574
Failure Code [DWN5KA] 1576
Failure Code [DWN5KB] 1579
Failure Code [DWN5KY] 1582
Failure Code [DWNSKA] 1584
Failure Code [DWNSKB] 1586
Failure Code [DWNSKY] 1588
Failure Code [DXA8KA] 1589
Failure Code [DXA8KB] 1591
Failure Code [DXE4KA] 1593
Failure Code [DXE4KB] 1595
Failure Code [DXE4KY] 1597
Failure Code [DXE7KA] 1599
Failure Code [DXE7KB] 1601
Failure Code [DXE7KY] 1603
Failure Code [DXE8KA] 1605
Failure Code [DXE8KB] 1607
Failure Code [DXE8KY] 1609
Failure Code [DXE9KA] 1611
Failure Code [DXE9KB] 1613
Failure Code [DXE9KY] 1615
Failure Code [DXEAKA] 1617
Failure Code [DXEAKB] 1619
Failure Code [DXEAKY] 1621
Failure Code [DY20KA] 1623
Failure Code [DY20MA] 1625
Failure Code [DY2CKB] 1627
Failure Code [DY2DKB] 1630
Failure Code [DY2EKB] 1632
Failure Code [F311KA] 1634
Failure Code [F311KB] 1636
Failure Code [F312KA] 1638
Failure Code [F312KB] 1640
Failure Code [F313KA] 1642
Failure Code [F313KB] 1644
Failure Code [F314KA] 1647
Failure Code [F314KB] 1649
Failure Code [F315KB] 1651
Failure Code [F315KY] 1653
Failure Code [F316KB] 1655
Failure Code [F316KY] 1657
Failure Code [F318KB] 1659
Failure Code [F318KY] 1662
Failure Code [F31AKB] 1664
Failure Code [F31AKY] 1666
Failure Code [F31BKB] 1668
Failure Code [F31BKY] 1670
Failure Code [F31CKB] 1672
Failure Code [F31CKY] 1674
Failure Code [F31DKB] 1676
Failure Code [F31DKY] 1678
Failure Code [F31EKB] 1680
Failure Code [F31EKY] 1682
Troubleshooting of Electrical System (E-Mode) 1684
E-1 Engine Does Not Start (Engine Does Not Crank) 1684
E-2 Manual Preheating System Does Not Operate 1690
E-3 Automatic Preheating System Does Not Operate 1693
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1695
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1697
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1700
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1701
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1702
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1703
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1704
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1705
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1706
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1707
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1708
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1709
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1710
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1711
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1713
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1714
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1715
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1716
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1718
E-23 Some Areas of Machine Monitor Screen are Not Shown 1719
E-24 Function Switch Does Not Operate 1720
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1721
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1722
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1723
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1724
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1725
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1726
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1727
E-32 Alarm Buzzer Cannot be Canceled 1729
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1730
E-34 Service Mode Cannot be Selected 1731
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1732
E-36 All Work Equipment, Swing and Travel Do Not Lock 1735
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1737
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1740
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1742
E-40 One-Touch Power Maximizing Function is Not Cancelled 1745
E-41 Alarm Does Not Sound During Travel 1746
E-42 Alarm Does Not Stop When Machine Stops 1748
E-43 Horn Does Not Sound 1749
E-44 Horn Does Not Stop 1752
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1754
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1755
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1757
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1758
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1759
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1760
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1761
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1762
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1763
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1764
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1765
E-56 Service is Not Shown Correctly with Monitoring Function 1766
E-57 Attachment Hydraulic Circuit Cannot be Changed 1768
E-58 KOMTRAX System Does Not Operate Correctly 1769
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1770
Information Shown in Troubleshooting Table (H-Mode) 1770
Failure Mode and Cause Table 1771
H-1 All Work Equipment, Swing and Travel Do Not Work 1781
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1782
H-3 Fine Control Performance or Response is Unsatisfactory 1784
H-4 Unusual Noise is Heard from Around Hydraulic Pump 1785
H-5 Engine Speed Drops Largely or Engine Stops 1786
H-6 Speed or Power of Boom is Low 1788
H-7 Arm Speed or Power is Low 1791
H-8 Bucket Speed or Power is Low 1795
H-9 Work Equipment Does Not Move in Single Operation 1797
H-10 Hydraulic Drift of Boom is Large 1798
H-11 Hydraulic Drift of Arm is Large 1799
H-12 Hydraulic Drift of Bucket is Large 1801
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1802
H-14 Time Lag of Work Equipment is Large 1803
H-15 One-Touch Power Maximizing Function Does Not Operate 1804
H-16 Attachment Circuit Cannot be Changed 1805
H-17 Oil Flow in Attachment Circuit Cannot be Changed 1806
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1807
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 1808
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1809
H-21 Machine Does Not Travel Straight 1810
H-22 Machine is Not Steered Correctly or Steering Power is Low 1813
H-23 Travel Speed is Low 1815
H-24 One of Tracks Does Not Run 1817
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1818
H-26 Upper Structure Does Not Swing to Right and Left 1819
H-27 Upper Structure Swings Only to Right or Left 1820
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 1821
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 1822
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1823
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1824
H-32 Shock is Large When Upper Structure Stops Swing Operation 1825
H-33 There is Large Unusual Noise When It Stops Swing Operation 1826
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1827
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1828
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1829
H-37 Unusual Noise is Heard from Around Fan 1830
Troubleshooting of Engine (S-Mode) 1831
Information Shown in Troubleshooting Table (S-Mode) 1831
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1832
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1833
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1834
S-4 Engine Startability is Unsatisfactory 1836
S-5 Engine Does Not Pick Up Smoothly 1838
S-6 Engine Stops During Operation 1840
S-7 Engine Runs Rough or is Not Stable 1842
S-8 Engine Lacks Power 1843
S-9 Exhaust Smoke is Black 1845
S-10 Engine Oil Consumption is Excessive 1847
S-11 Oil Becomes Dirty Quickly 1848
S-12 Fuel Consumption is Excessive 1849
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1850
S-14 Oil Pressure Drops 1851
S-15 Fuel Mixes Into Engine Oil 1853
S-16 Water Mixes Into Engine Oil (Milky) 1854
S-17 Coolant Temperature Increases Too High (Overheating) 1855
S-18 Unusual Noise is Heard 1856
S-19 Vibration is Excessive 1857
S-20 Air Cannot be Bled from Fuel Circuit 1858
S-21 Active Regeneration is Done Frequently 1859
S-22 Active Regeneration Continues Long 1860
S-23 White Smoke is Exhausted During Active Regeneration 1861
S-24 DEF Consumption is Excessive 1862
S-25 There is Unusual Smell (Irritating Odor) 1864
S-26 Foreign Materials Enter DEF (DEF Increases) 1865
50 Disassembly and Assembly 1867
Table of Contents 1868
Precautions Before Work 1873
Related Information on Disassembly and Assembly 1874
How to Read This Manual 1874
Coating Materials List 1876
Special Tool List 1881
Sketches of Special Tools 1895
Engine and Cooling System 1903
Remove and Install Supply Pump Assembly 1903
How to Remove Supply Pump Assembly 1903
How to Install Supply Pump Assembly 1907
Remove and Install Injector Assembly 1911
How to Remove Injector Assembly 1911
How to Install Injector Assembly 1914
Remove and Install Cylinder Head Assembly 1920
How to Remove Cylinder Head Assembly 1920
How to Install Cylinder Head Assembly 1930
Remove and Install EGR Valve Assembly 1947
How to Remove EGR Valve Assembly 1947
How to Install EGR Valve Assembly 1948
Remove and Install EGR Cooler Assembly 1950
How to Remove EGR Cooler Assembly 1950
How to Install EGR Cooler Assembly 1952
Remove and Install Starter Assembly 1955
How to Remove Starting Motor Assembly 1955
How to Install Starting Motor Assembly 1957
Remove and Install Alternator Belt 1960
How to Remove Alternator Belt 1960
How to Install Alternator Belt 1962
Remove and Install Radiator Assembly 1965
How to Remove Radiator Assembly 1965
How to Install Radiator Assembly 1969
Remove and Install Hydraulic Oil Cooler Assembly 1973
How to Remove Hydraulic Oil Cooler Assembly 1973
How to Install Hydraulic Oil Cooler Assembly 1977
Remove and Install Aftercooler Assembly 1981
How to Remove Aftercooler Assembly 1981
How to Install Aftercooler Assembly 1983
Remove and Install Fan Clutch Assembly 1986
How to Remove Fan Clutch Assembly 1986
How to Install Fan Clutch Assembly 1990
Remove and Install Fan 1994
How to Remove Fan 1994
How to Install Fan 1994
Remove and Install Engine and Main Pump Assembly 1995
How to Remove Engine and Main Pump Assembly 1995
How to Install Engine and Main Pump Assembly 2011
Remove and Install Engine Front Oil Seal 2028
How to Remove Engine Front Oil Seal 2028
How to Install Engine Front Oil Seal 2032
Remove and Install Engine Rear Oil Seal 2038
How to Remove Engine Rear Oil Seal 2038
How to Install Engine Rear Oil Seal 2039
Remove and Install Fuel Cooler Assembly 2042
How to Remove Fuel Cooler Assembly 2042
How to Install Fuel Cooler Assembly 2044
Remove and Install Engine Hood Assembly 2047
How to Remove Engine Hood Assembly 2047
How to Install Engine Hood Assembly 2049
Remove and Install KDOC Assembly 2055
How to Remove KDOC Assembly 2055
How to Install KDOC Assembly 2058
Remove and Install KDOC and SCR Assembly 2061
How to Remove KDOC and SCR Assembly 2061
How to Install KDOC and SCR Assembly 2068
Remove and Install Bellows Pipe Assembly 2075
How to Remove Bellows Pipe Assembly 2075
How to Install Bellows Pipe Assembly 2077
Remove and Install Fuel Tank Assembly 2082
How to Remove Fuel Tank Assembly 2082
How to Install Fuel Tank Assembly 2087
Remove and Install DEF Tank Assembly 2093
How to Remove DEF Tank Assembly 2093
How to Install DEF Tank Assembly 2101
Remove and Install DEF Tank Sensor Flange Assembly 2107
How to Remove DEF Tank Sensor Flange Assembly 2107
How to Install DEF Tank Sensor Flange Assembly 2108
Remove and Install DEF Tank Sensor 2110
How to Remove DEF Tank Sensor 2110
How to Install DEF Tank Sensor 2111
Remove and Install DEF Tank Strainer 2113
How to Remove DEF Tank Strainer 2113
How to Install DEF Tank Strainer 2113
Remove and Install DEF Tank Filler Port Filter 2114
How to Remove DEF Tank Filler Port Filter 2114
How to Install DEF Tank Filler Port Filter 2116
Remove and Install SCR Assembly 2119
How to Remove SCR Assembly 2119
How to Install SCR Assembly 2121
Remove and Install KCCV Assembly 2123
How to Remove KCCV Assembly 2123
How to Install KCCV Assembly 2124
Remove and Install DEF Mixing Tube 2126
How to Remove DEF Mixing Tube 2126
How to Install DEF Mixing Tube 2133
Remove and Install DEF Injector 2139
How to Remove DEF Injector 2139
How to Install DEF Injector 2142
Remove and Install DEF Pump 2145
How to Remove DEF Pump 2145
How to Install DEF Pump 2148
Remove and Install DEF Hose 2151
How to Remove DEF Hose 2151
How to Install DEF Hose 2161
Remove and Install Air Cleaner Assembly 2171
How to Remove Air Cleaner Assembly 2171
How to Install Air Cleaner Assembly 2172
Remove and Install Air Conditioner Compressor Assembly 2175
How to Remove Air Conditioner Compressor Assembly 2175
How to Install Air Conditioner Compressor Assembly 2177
Remove and Install Air Conditioner Condenser Assembly 2180
How to Remove Air Conditioner Condenser Assembly 2180
How to Install Air Conditioner Condenser Assembly 2181
Power Train 2183
Remove and Install Travel Motor and Final Drive Assembly 2183
How to Remove Travel Motor and Final Drive Assembly 2183
How to Install Travel Motor and Final Drive Assembly 2184
Disassemble and Assemble Final Drive Assembly 2185
How to Disassemble Final Drive Assembly 2186
How to Assemble Final Drive Assembly 2189
Remove and Install Swing Motor and Swing Machinery Assembly 2197
How to Remove Swing Motor and Swing Machinery Assembly 2197
How to Install Swing Motor and Swing Machinery Assembly 2199
Disassemble and Assemble Swing Machinery Assembly 2201
How to Disassemble Swing Machinery Assembly 2201
How to Assemble Swing Machinery Assembly 2205
Remove and Install Swing Circle Assembly 2212
How to Remove Swing Circle Assembly 2212
How to Install Swing Circle Assembly 2212
Undercarriage and Frame 2214
Separate and Connect Track Assembly 2214
How to Separate Track Assembly 2214
How to Install Track Assembly 2215
Remove and Install Sprocket 2218
How to Remove Sprocket 2218
How to Install Sprocket 2219
Remove and Install Idler and Idler Cushion Assembly 2220
How to Remove Idler and Idler Cushion Assembly 2220
How to Install Idler and Idler Cushion Assembly 2221
Disassemble and Assemble Idler Assembly 2222
How to Disassemble Idler Assembly 2222
How to Assemble Idler Assembly 2223
Disassemble and Assemble Idler Cushion Assembly 2227
How to Disassemble Idler Cushion Assembly 2227
How to Assemble Idler Cushion Assembly 2228
Disassemble and Assemble Track Roller Assembly 2230
How to Disassemble Track Roller Assembly 2230
How to Assemble Track Roller Assembly 2231
Disassemble and Assemble Carrier Roller Assembly 2234
How to Disassemble Carrier Roller Assembly 2234
How to Assemble Carrier Roller Assembly 2236
Remove and Install Revolving Frame Assembly 2238
How to Remove Revolving Frame Assembly 2238
How to Install Revolving Frame Assembly 2241
Remove and Install Counterweight Assembly 2244
How to Remove Counterweight Assembly 2244
How to Install Counterweight Assembly 2245
Hydraulic System 2248
Remove and Install Center Swivel Joint Assembly 2248
How to Remove Center Swivel Joint Assembly 2248
How to Install Center Swivel Joint Assembly 2251
Disassemble and Assemble Center Swivel Joint Assembly 2254
How to Disassemble Center Swivel Joint Assembly 2254
How to Assemble Center Swivel Joint Assembly 2255
Remove and Install Hydraulic Tank Assembly 2257
How to Remove Hydraulic Tank Assembly 2257
How to Install Hydraulic Tank Assembly 2264
Remove and Install Main Pump Assembly 2272
How to Remove Main Pump Assembly 2272
How to Install Main Pump Assembly 2274
Remove and Install Control Valve Assembly 2277
How to Remove Control Valve Assembly 2277
How to Install Control Valve Assembly 2280
Disassemble and Assemble Control Valve Assembly 2284
How to Assemble Control Valve Assembly 2284
How to Replace Pressure Reducing Valve Cartridge Assembly 2286
Disassemble and Assemble Work Equipment PPC Valve Assembly 2289
How to Disassemble Work Equipment PPC Valve Assembly 2289
How to Assemble Work Equipment PPC Valve Assembly 2290
Work Equipment 2292
Remove and Install Work Equipment Assembly 2292
How to Remove Work Equipment Assembly 2292
How to Install Work Equipment Assembly 2295
Remove and Install Boom Anti-drop Valve Assembly 2299
How to Remove Boom Anti-drop Valve Assembly 2299
How to Install Boom Anti-drop Valve Assembly 2301
Remove and Install Arm Anti-Drop Valve Assembly 2302
How to Remove Arm Anti-Drop Valve Assembly 2302
How to Install Arm Anti-Drop Valve Assembly 2304
Disassemble and Assemble Anti-Drop Valve Assembly 2305
How to Disassemble Anti-Drop Valve Assembly 2305
How to Assemble Anti-Drop Valve Assembly 2305
Disassemble and Assemble Work Equipment Cylinder Assembly 2306
How to Disassemble Work Equipment Cylinder Assembly 2307
How to Assemble Work Equipment Cylinder Assembly 2309
CAB Related Parts 2315
Remove and Install Operator Cab Assembly 2315
How to Remove Operator Cab Assembly 2315
How to Install Operator Cab Assembly 2322
Remove and Install Operator Cab Glass (Adhered Glass) 2330
How to Remove Operator Cab Glass (Adhered Glass) 2332
How to Install Operator Cab Glass (Adhered Glass) 2332
Remove and Install Front Window Assembly 2342
How to Remove Front Window Assembly 2342
How to Install Front Window Assembly 2345
Remove and Install Floor Frame Assembly 2351
How to Remove Floor Frame Assembly 2351
How to Install Floor Frame Assembly 2355
Remove and Install Air Conditioner Unit Assembly 2360
How to Remove Air Conditioner Unit Assembly 2360
How to Install Air Conditioner Unit Assembly 2364
Remove and Install Operator Seat 2370
How to Remove Operator Seat 2370
How to Install Operator Seat 2372
How to Remove and Install Seat Belt 2375
How to Remove Seat Belt 2375
How to Install Seatbelt 2375
Remove and Install Work Equipment Control Lever Assembly 2377
How to Remove Work Equipment Control Lever Assembly 2377
How to Install Work Equipment Control Lever Assembly 2383
Remove and Install Front Wiper Assembly 2392
How to Remove Front Wiper Assembly 2392
How to Install Front Wiper Assembly 2397
Electrical System 2406
Remove and Install Engine Controller Assembly 2406
How to Remove Engine Controller Assembly 2406
How to Install Engine Controller Assembly 2408
Remove and Install Pump Controller Assembly 2411
How to Remove Pump Controller Assembly 2411
How to Install Pump Controller Assembly 2414
Remove and Install Machine Monitor Assembly 2417
How to Remove Machine Monitor Assembly 2417
How to Install Machine Monitor Assembly 2419
Remove and Install Pump Swash Plate Sensor 2423
How to Remove Pump Swash Plate Sensor 2423
How to Install Pump Swash Plate Sensor 2423
Remove and Install Mass Air Flow and Temperature Sensor 2425
How to Remove Mass Air Flow and Temperature Sensor 2425
How to Install Mass Air Flow and Temperature Sensor 2426
Remove and Install KCCV Crankcase Pressure Sensor 2428
How to Remove KCCV Crankcase Pressure Sensor 2428
How to Install KCCV Crankcase Pressure Sensor 2429
Remove and Install SCR Temperature Sensor 2431
How to Remove SCR Temperature Sensor 2431
How to Install SCR Temperature Sensor 2432
Remove and Install Gateway Function Controller Assembly 2434
How to Remove Gateway Function Controller Assembly 2434
How to Install Gateway Function Controller Assembly 2439
Remove and Install Communication Terminal Wiring Harness 2444
How to Remove Communication Terminal Wiring Harness 2444
How to Install Communication Terminal Wiring Harness 2452
Remove and Install Communication Terminal 2461
How to Remove Communication Terminal 2461
How to Install Communication Terminal 2463
60 Maintenance Standard 2467
Table of Contents 2468
Engine and Cooling System 2469
Maintenance Standard for Engine Mount 2469
Maintenance Standard for Cooling System 2470
Power Train 2472
Maintenance Standard for Swing Circle 2472
Maintenance Standard for Swing Machinery 2473
Maintenance Standard for Final Drive 2475
Maintenance Standard for Sprocket 2477
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2478
Undercarriage and Frame 2479
Maintenance Standard for Track Frame and Idler Cushion 2479
Maintenance Standard for Idler 2481
Maintenance Standard for Track Roller 2483
Maintenance Standard for Carrier Roller 2484
Maintenance Standard for Track Shoes 2485
Maintenance Standard for Triple Shoes 2488
Hydraulic System 2489
Maintenance Standard for Hydraulic Tank 2489
Maintenance Standard for Main Pump 2490
Maintenance Standard for PC-EPC Valve 2492
Maintenance Standard for Travel Motor 2493
Maintenance Standard for Control Valve 2496
Maintenance Standard for Boom Anti-Drop Valve 2507
Maintenance Standard for Arm Anti-Drop Valve 2509
Maintenance Standard for Work Equipment and Swing PPC Valve 2511
Maintenance Standard for Travel PPC Valve 2514
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2517
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2518
Maintenance Standard for 2nd-Line Attachment PPC Valve 2520
Maintenance Standard for Solenoid Valve 2522
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2523
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2524
Maintenance Standard for Center Swivel Joint 2525
Work Equipment 2526
Maintenance Standard for Work Equipment Linkage 2526
Dimensions of Arm 2531
Dimensions of Bucket 2533
Maintenance Standard for Boom Cylinder 2535
Maintenance Standard for Arm Cylinder 2536
Maintenance Standard for Bucket Cylinder 2537
80 Appendix 2539
Table of Contents 2540
Precautions Before Work 2542
Air Conditioner System 2543
Precautions for Refrigerant 2543
Air Conditioner Component 2544
Specifications of Air Conditioner 2546
Structure and Function of Refrigeration Cycle 2547
Outline of Refrigeration Cycle 2548
Component Parts of Air Conditioner System 2550
Air Conditioner Unit 2550
Configuration Diagram of Air Conditioner Unit 2550
Function of Air Conditioner Unit 2552
Component Parts of Air Conditioner Unit 2554
Function of Evaporator as Air Conditioner Unit Component 2555
Function of Heater Core as Air Conditioner Unit Component 2555
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2555
Function of Servo Motor as Air Conditioner Unit Component 2555
Structure of Expansion Valve as Air Conditioner Unit Component 2556
Function of Expansion Valve as Air Conditioner Unit Component 2556
Operate Expansion Valve as Air Conditioner Unit Component 2556
Function of Dual Pressure Switch 2557
Air Conditioner Controller 2558
Structure of Air Conditioner Controller 2558
Compressor 2559
Structure of Compressor 2559
Specifications of Compressor 2559
Function of Compressor 2559
Condenser 2560
Structure of Condenser 2560
Specifications of Condenser 2560
Function of Condenser 2560
Air Conditioner Related Sensors 2562
Structure of Sunlight Sensor 2562
Function of Sunlight Sensor 2562
Structure of Outside Temperature Sensor 2562
Function of Outside Air Temperature Sensor 2562
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2564
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2566
System Diagram of Air Conditioner 2568
Input and Output Signals of Air Conditioner Controller 2569
Function of Air Conditioner Controller 2570
Locations of Air Conditioner Parts and Layout of Connectors 2571
Examine Air Leakage (Duct) 2575
How to Examine Air Leakage (Duct) 2575
Examine Air Conditioner with Self-Diagnosis Function 2577
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2578
Examine Vent (Mode) Changeover 2579
How to Examine Vent (Mode) Changeover 2579
Examine Fresh/Recirc Air Changeover 2581
How to Examine Fresh/Recirc Air Changeover 2581
Examine Sunlight Sensor 2582
How to Examine Sunlight Sensor 2582
Examine Refrigerant (Dual) Pressure Switch 2583
How to Examine Refrigerant (Dual) Pressure Switch 2583
Examine Relay 2584
How to Examine Relay 2584
Air Conditioner Troubleshooting Chart 1 2585
Air Conditioner Troubleshooting Chart 2 2586
Information Shown in Troubleshooting Table 2589
Failure Code [879AKA] 2590
Failure Code [879AKB] 2591
Failure Code [879BKA] 2592
Failure Code [879BKB] 2594
Failure Code [879CKA] 2596
Failure Code [879CKB] 2597
Failure Code [879DKZ] 2598
Failure Code [879EMC] 2600
Failure Code [879FMC] 2601
Failure Code [879GKX] 2602
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2604
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2606
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2609
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2611
Troubleshooting by Gauge Pressure 2613
Connect Service Tool 2616
How to Connect Service Tool 2616
Precautions for Disconnection and Connection of Air Conditioner Piping 2618
Handle Compressor Oil 2620
How to Replace Desiccant 2622
90 Circuit Diagrams 2625
Table of Contents 2626
Hydraulic Circuit Diagram 2627
Symbols Used in Hydraulic Circuit Diagram 2627
Hydraulic Circuit Diagram 2631
Electrical Circuit Diagram 2633
Symbols Used in Electric Circuit Diagram 2633
Electrical Circuit Diagram (1/9) 2637
Electrical Circuit Diagram (2/9) 2639
Electrical Circuit Diagram (3/9) 2641
Electrical Circuit Diagram (4/9) 2643
Electrical Circuit Diagram (5/9) 2645
Electrical Circuit Diagram (6/9) 2647
Electrical Circuit Diagram (7/9) 2649
Electrical Circuit Diagram (8/9) 2651
Electrical Circuit Diagram (9/9) 2653
Index 2655

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24