Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-05 PDF

Description

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-05 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-05 – PDF DOWNLOAD 

Language : English
Pages : 2718
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-05 – PDF DOWNLOAD 

SERIAL NUMBERS 35877 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 SEN06806-05 – PDF DOWNLOAD 

SERIAL NUMBERS 35877 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC170LC-11 93
Working Range Drawings 95
Working Range Drawings: PC170LC-11 95
Specifications 96
Specification: PC170LC-11 96
Weight Table 99
Weight Table: PC170LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 107
Urea SCR System Diagram 112
Function of Urea SCR System 113
Function of DEF System 113
Inducement Strategy 115
Component Parts of Urea SCR System 123
DEF Mixing Tube 123
SCR Assembly 123
DEF Tank 126
DEF Pump 128
DEF Injector 129
DEF Hose 130
DEF Tank Heating Valve 131
Boot-up System 132
Layout Drawing of Boot-up System 132
System Operating Lamp System 134
System Diagram of System Operating Lamp System 134
Function of Operation Lamp System 134
Battery Isolator 136
Function of Battery Isolator 136
Engine System 137
Layout Drawing of Engine System 137
Specifications of Engine System 138
Function of Engine System 138
Engine Control System 139
System Diagram of Engine Control 139
Function of Engine Control System 140
Auto-Deceleration System 143
System Diagram of Auto-Deceleration System 143
Function of Auto-Deceleration System 143
Operation of Auto-Deceleration System 144
Engine Automatic Warm-up System 145
System Diagram of Engine Automatic Warm-up System 145
Function of Engine Automatic Warm-up System 145
Overheat Prevention System 147
Overheat Prevention System Diagram 147
Function of Overheat Prevention System 147
Turbocharger Protection System 149
System Diagram of Turbocharger Protection System 149
Function of Turbocharger Protection System 149
Automatic Idle Stop System 151
System Diagram of Automatic Idle Stop System 151
Function of Automatic Idle Stop System 151
Component Parts of Engine System 154
VGT 154
EGR System 156
EGR Valve 158
EGR Cooler 160
KCCV System 161
KCCV Ventilator 163
KDOC 165
Cooling System 169
Layout Drawing of Cooling System 169
Specifications of Cooling System 170
Fan Speed Control System of Fan Clutch 171
Fan Speed Control System Diagram of Fan Clutch 171
Function of Fan Speed Control System of Fan Clutch 172
Engine Output Control System of Fan Clutch 173
Engine Output Control System Diagram of Fan Clutch 173
Function of Engine Output Control System of Fan Clutch 173
Component Parts of Cooling System 175
Fan Clutch 175
Control System 176
Layout Drawing of Control System 176
Machine Monitor System 179
System Diagram of Machine Monitor System 179
Function of Machine Monitor System 179
KomVision System 181
Layout Drawing of KomVision System 181
System Diagram of KomVision System 183
Function of KomVision System 183
KOMTRAX System 185
System Diagram of KOMTRAX System 185
Function of KOMTRAX System 185
PPC Levers 186
LH PPC Lever 186
RH PPC Lever 187
Automatic Grease System 188
Outline of AUTO Grease System 188
Component Parts of Control System 200
Machine Monitor 200
KomVision Controller 213
KomVision Camera 217
Gateway Function Controller 218
Communication Terminal 221
Pump Controller 223
Resistor for PC-EPC Valve 227
CAN Terminating Resistor 227
PPC Oil Pressure Switch 228
Engine Controller 229
Fuel Control Dial 235
Hydraulic System 238
Layout Drawing of Hydraulic System 238
CLSS 242
Structure of CLSS 242
Function of CLSS 243
Engine and Pump Combined Control System 245
Engine and Pump Combined Control System Diagram 245
Function of Engine and Pump Combined Control System 246
Pump and Valve Control System 251
Pump and Valve Control System Diagram 251
Function of Pump and Valve Control System 252
Component Parts of Hydraulic System 254
Hydraulic Tank 254
Main Pump 256
Pilot Oil Filter 279
Control Valve 279
Work Equipment System 344
Layout Drawing of Work Equipment System 344
One-Touch Power Maximizing System 348
System Diagram of One-Touch Power Maximizing System 348
Function of One-Touch Power Maximizing System 348
PPC Lock System 350
System Diagram of PPC Lock 350
Function of PPC Lock System 350
Work Equipment and Travel Automatic Lock System 351
System Diagram of Lock Lever Automatic Lock System 351
Function of Work Equipment and Travel Automatic Lock System 351
Operation of Lock Lever Automatic Lock System 352
Attachment Oil Flow Adjuster System 353
Attachment Oil Flow Adjuster System Diagram 353
Function of Attachment Oil Flow Adjuster System 354
Component Parts of Work Equipment System 355
Work Equipment and Swing PPC Valve 355
1st-Line Attachment PPC Valve (with EPC Valve) 361
2nd-Line Attachment PPC Valve 367
Solenoid Valve 370
Boom Anti-drop Valve 372
Arm Anti-Drop Valve 376
Attachment Circuit Selector Valve (For High Pressure) 380
Attachment Circuit Selector Valve (For Low Pressure) 382
Pilot Circuit Accumulator 385
Attachment Circuit Accumulator 386
Swing System 387
Layout Drawing of Swing System 387
Swing Control System Diagram 391
Function of Swing Control System 391
Component Parts of Swing System 394
Swing Motor 394
Swing Machinery 397
Swing Circle 399
Travel System 401
Layout Drawing of Travel System 401
System Diagram of Travel Control System 404
Function of Travel Control System 404
Component Parts of Travel System 406
Travel Motor 406
Final Drive 418
Travel PPC Valve 419
Center Swivel Joint 424
Undercarriage and Frame 426
Layout Drawing of Undercarriage 426
Specifications of Undercarriage 427
Work Equipment 428
Structure of Work Equipment 428
Function of Work Equipment 429
Work Equipment Clearance Adjustment Shim 430
Function of Work Equipment Clearance Adjustment Shim 430
Bucket Clearance Adjustment Shim 431
Function of Bucket Clearance Adjustment Shim 431
CAB Related Parts 432
ROPS CAB 432
Structure of ROPS CAB 432
Function of ROPS CAB 432
CAB Mount 433
Structure of CAB Mount 433
Function of CAB Mount 433
CAB Tipping Stopper 434
Structure of CAB Tipping Stopper 434
Function of CAB Tipping Stopper 434
20 Standard Value Table 435
Table of Contents 436
Standard Value Table for Engine 437
Standard Value Table for Engine: PC170LC-11 437
Standard Value Table for Machine 441
Standard Value Table for Machine: PC170LC-11 441
Machine Posture and Procedures to Measure Performance 454
30 Testing and Adjusting 459
Table of Contents 460
Precautions Before Work 463
Related Information on Testing and Adjusting 464
Tools for Testing and Adjusting 464
Sketch of Tools for Testing and Adjusting 471
Engine and Cooling System 473
Examine Engine Speed 473
How to Examine Engine Speed 473
Examine Boost Pressure 475
How to Examine Boost Pressure on Machine Monitor 475
How to Examine Boost Pressure by Testing Tool 476
Examine Exhaust Gas Color 477
How to Examine Exhaust Gas Color with the Handy Smoke Checker 477
How to Examine Exhaust Gas Color with Smoke Meter 478
Examine and Adjust Valve Clearance 479
How to Examine Valve Clearance 479
How to Adjust Valve Clearance 480
Examine Compression Pressure 482
How to Examine Compression Pressure 482
Examine Blowby Pressure 487
How to Examine Blowby Pressure 487
Examine Engine Oil Pressure 489
How to Examine Engine Oil Pressure 489
Examine Fuel Pressure 490
How to Examine Fuel Pressure 491
Examine Fuel Discharge, Return and Leakage 495
How to Examine Fuel Discharge, Return, and Leakage 496
Bleed Air from Fuel System 500
How to Bleed Air from Fuel System 500
Examine Fuel Circuit for Leakage 501
How to Examine Fuel System for Leakage 501
Handle Cylinder Cut-out Mode Operation 503
Handle No-Injection Cranking Operation 504
Examine and Adjust Air Conditioner Compressor Belt Tension 505
How to Examine Air Conditioner Compressor Belt 505
How to Adjust Air Conditioner Compressor Belt 505
Examine Fan Belt and Alternator Belt 507
How to Examine Fan Belt and Alternator Belt 507
Examine Automatic Tensioner 508
How to Examine Automatic Tensioner 508
How to Replace Fan Belt 509
Examine Cooling Fan Speed 510
How to Examine Cooling Fan Speed 510
Examine SCR Related Functions 511
Examine DEF Pump Raised Pressure 514
Examine Injection Volume from DEF Injector 516
Examine DEF Line Heater Relay 1 520
Examine DEF Line Heater Relay 2 523
Examine DEF Pump Heater Relay 525
Examine DEF Tank Heater Valve 529
Examine SCR Denitration Efficiency 531
Clean DEF Tank 535
How to Clean DEF Tank 535
Clean DEF Pump 539
How to Clean DEF Pump 539
Bleed Air from Coolant Circuit of DEF Tank 546
How to Bleed Air from Coolant Circuit of DEF Tank 546
Power Train 548
Examine Swing Circle Bearing Clearance 548
How to Examine Swing Circle Bearing Clearance 548
Undercarriage and Frame 549
Examine and Adjust Track Tension 549
How to Examine Track Tension 549
How to Adjust Track Tension 549
Hydraulic System 551
Release Remained Pressure in Hydraulic Circuit 551
How to Release Remained Pressure from Hydraulic Tank 551
How to Release Remained Pressure in Hydraulic Cylinder Circuit 551
How to Release Remained Pressure from Swing Motor Circuit 553
How to Release Remained Pressure from Travel Motor Circuit 553
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 554
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 554
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 560
Examine Oil Pressure of Control Circuit 562
How to Examine Oil Pressure in Control Circuit 562
Examine and adjust oil pressure in pump PC control circuit 564
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 564
How to Examine PC-EPC Valve Outlet Pressure 565
How to Adjust Oil Pressure in Pump PC Control Circuit 566
Examine and Adjust Oil Pressure in Pump LS Control Circuit 568
How to Examine LS Differential Pressure with Machine Monitor 568
How to Examine LS Differential Pressure by Testing Tool 570
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 572
How to Adjust LS Valve 573
Examine Outlet Pressure of Solenoid Valve 574
How to Examine Outlet Pressure of Solenoid Valve 574
Operating Condition of Solenoid Valve 575
Examine PPC Valve Outlet Pressure 578
How to Examine Outlet Pressure in PPC Valve 578
Adjust Play of Work Equipment and Swing PPC Valves 580
How to Adjust Play of Work Equipment and Swing PPC Valves 580
Measure and Adjust Quick Coupler Control Valve Output Pressure 581
Examine Pump Swash Plate Sensor 583
How to Examine pump swash plate sensor 583
Examine and Adjust Travel Deviation 584
How to Examine Travel Deviation 584
How to Adjust Travel Deviation 584
Examine Parts Which Cause Hydraulic Drift of Work Equipment 587
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 587
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 587
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 588
Examine Oil Leakage 589
How to Examine Oil Leakage from Boom Cylinder 589
How to Examine Oil Leakage from Arm Cylinder 589
How to Examine Oil Leakage from Bucket Cylinder 590
How to Examine Oil Leakage from Swing Motor 591
How to Examine Oil Leakage from Travel Motor 591
Bleed Air from Hydraulic System 592
How to Bleed Air from Hydraulic System 593
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 596
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 596
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 600
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 600
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 604
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 604
CAB Related Parts 611
Examine CAB Tipping Stopper 611
How to Examine Cab Tipping Stopper 611
How to Adjust Mirrors 612
Procedure to Adjust Machine Left Front Mirror (A) 612
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 613
Procedure to Adjust Machine Right Front Mirror (B) 614
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 615
Procedure to Adjust Machine Right Side Mirror (C) 617
Electrical System 618
Set and Operate Machine Monitor 618
Operator Mode 621
Function to Show Technician Identification Status Screen 622
Function to Show Operator Identification Input Screen 622
Examine Function by LCD (Liquid Crystal Display) 623
Examine Function of Service Meter 623
Usage Limitation and Maintenance Password Change Function 623
Service Mode 626
How to Operate Service Mode 626
How to See Pre-defined Monitoring Information 627
How to Examine Self-Define Monitor Information 634
Abnormality Record Menu 644
How to See Maintenance Record 648
Maintenance Mode Setting 649
How to Set Phone Number Entry 653
Default Menu 654
Diagnostic Tests Menu 662
Adjustment Menu 669
No-Injection Cranking Operation 691
KOMTRAX Settings Menu 692
How to Show Service Message 694
How to Start Up KOMTRAX System 696
Adjust Rearview Camera Angle 701
How to Adjust Rearview Camera Angle 701
Adjust KomVision Camera Angle 704
How to Adjust KomVision Camera Angle 705
Adjust KomVision Related Function 709
Setting of KomVision (Main Setting) 709
Setting of KomVision (Camera Setting) 711
Setting of KomVision (Camera Calibration) 713
KomVision screen – Check 12 m visibility 726
Handle Voltage Circuit of Engine Controller 729
Handle Battery Isolator Switch 730
Examine Diodes 731
How to Examine Diodes by Digital Tester 731
How to Examine Diodes by Analog Tester 731
Pm Clinic 732
Pm Clinic Service 732
Pm Clinic Check Sheet: PC170LC-11 736
40 Troubleshooting 747
Table of Contents 748
Precautions Before Work 758
Related Information to Troubleshooting 759
General Troubleshooting Points 759
Troubleshooting Points for Urea SCR System 760
Sequence of Events in Troubleshooting 774
Checks Before Troubleshooting 776
Inspection Procedure Before Troubleshooting 778
Walk-Around Check 778
Test in Accordance with Testing Procedure 780
Examine Fuel Level and Type 780
Examine for Impure Ingredient in Fuel 780
Examine Fuel Prefilter 781
Examine Water Separator, Drain Water and Sediment 781
How to Replace Fuel Prefilter Cartridge 782
Examine Fuel Main Filter 784
Examine Engine Oil Level (Oil Quantity in Oil Pan) 785
Examine Coolant Level (Reservoir Tank) 786
Examine Air Cleaner Clogging 787
Clean Outer Element 787
Replace Element 790
Examine Hydraulic Oil Level 792
Examine Hydraulic Oil Strainer 793
Examine Hydraulic Oil Filter 794
Examine Oil Level in Swing Machinery Case 795
Examine Oil Level in Damper Case 796
Examine Oil Level in Final Drive Case 796
Bleed Air from Fuel System 797
Bleed Air from Hydraulic System 797
How to Examine Electric Equipment 797
Automatic Grease System 803
Find Malfunctions 803
Malfunction Finding Procedures 805
Preparation for Troubleshooting of Electrical System 807
Preparation for Troubleshooting of Machine Monitor 807
Preparation for Troubleshooting of Engine Controller 807
Preparation for Troubleshooting of Pump Controller 807
Preparation for Troubleshooting of Gateway Function Controller 807
How to Disconnect and Connect Connector with a Special Lock 808
Procedure for Troubleshooting 812
Symptom and Troubleshooting Numbers 815
Information Shown in Troubleshooting Table 819
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 821
Connector List and Layout 824
Connector Contact Connection Table 837
T-Branch Box and T-Branch Adapter Table 877
Fuse Location Table 883
Precautions When You Replace KDOC 886
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 887
Failure Code Table 889
Troubleshooting by Failure Code (Display of Code) 907
Failure Code [879AKA] 907
Failure Code [879AKB] 908
Failure Code [879BKA] 909
Failure Code [879BKB] 911
Failure Code [879CKA] 913
Failure Code [879CKB] 914
Failure Code [879DKZ] 915
Failure Code [879EMC] 917
Failure Code [879FMC] 918
Failure Code [879GKX] 919
Failure Code [989L00] 921
Failure Code [989M00] 922
Failure Code [989N00] 923
Failure Code [A1U0N3] 924
Failure Code [A1U0N4] 926
Failure Code [A900FR] 928
Failure Code [A900N6] 929
Failure Code [A900NY] 930
Failure Code [AA10NX] 931
Failure Code [AB00KE] 933
Failure Code [AQ10MB] 936
Failure Code [AQ10N3] 938
Failure Code [AS00N3] 940
Failure Code [AS00R2] 942
Failure Code [AS00R3] 943
Failure Code [AS00R4] 944
Failure Code [AS00R5] 945
Failure Code [AS00R6] 946
Failure Code [AS00ZK] 947
Failure Code [AS10KM] 948
Failure Code [AS10NR] 949
Failure Code [AS10NT] 951
Failure Code [B@BAZG] 952
Failure Code [B@BAZK] 953
Failure Code [B@BCNS] 955
Failure Code [B@BCZK] 956
Failure Code [B@HANS] 958
Failure Code [CA115] 959
Failure Code [CA122] 960
Failure Code [CA123] 962
Failure Code [CA131] 964
Failure Code [CA132] 966
Failure Code [CA144] 968
Failure Code [CA145] 970
Failure Code [CA153] 972
Failure Code [CA154] 975
Failure Code [CA187] 978
Failure Code [CA221] 980
Failure Code [CA222] 982
Failure Code [CA227] 984
Failure Code [CA234] 986
Failure Code [CA238] 987
Failure Code [CA239] 988
Failure Code [CA249] 989
Failure Code [CA256] 991
Failure Code [CA271] 993
Failure Code [CA272] 995
Failure Code [CA295] 997
Failure Code [CA322] 998
Failure Code [CA324] 1000
Failure Code [CA331] 1002
Failure Code [CA332] 1004
Failure Code [CA343] 1006
Failure Code [CA351] 1007
Failure Code [CA352] 1009
Failure Code [CA356] 1011
Failure Code [CA357] 1013
Failure Code [CA386] 1015
Failure Code [CA428] 1016
Failure Code [CA429] 1018
Failure Code [CA435] 1020
Failure Code [CA441] 1022
Failure Code [CA442] 1024
Failure Code [CA451] 1026
Failure Code [CA452] 1028
Failure Code [CA488] 1030
Failure Code [CA515] 1031
Failure Code [CA516] 1033
Failure Code [CA553] 1035
Failure Code [CA555] 1036
Failure Code [CA556] 1037
Failure Code [CA559] 1038
Failure Code [CA595] 1041
Failure Code [CA687] 1043
Failure Code [CA689] 1045
Failure Code [CA691] 1047
Failure Code [CA692] 1049
Failure Code [CA697] 1051
Failure Code [CA698] 1052
Failure Code [CA731] 1053
Failure Code [CA778] 1055
Failure Code [CA1117] 1060
Failure Code [CA1664] 1062
Failure Code [CA1669] 1064
Failure Code [CA1673] 1065
Failure Code [CA1677] 1066
Failure Code [CA1678] 1067
Failure Code [CA1682] 1068
Failure Code [CA1683] 1070
Failure Code [CA1684] 1072
Failure Code [CA1686] 1074
Failure Code [CA1691] 1075
Failure Code [CA1694] 1077
Failure Code [CA1695] 1079
Failure Code [CA1696] 1080
Failure Code [CA1712] 1082
Failure Code [CA1713] 1085
Failure Code [CA1714] 1087
Failure Code [CA1715] 1088
Failure Code [CA1776] 1089
Failure Code [CA1777] 1091
Failure Code [CA1843] 1094
Failure Code [CA1844] 1096
Failure Code [CA1885] 1098
Failure Code [CA1887] 1100
Failure Code [CA1896] 1102
Failure Code [CA1898] 1103
Failure Code [CA1938] 1105
Failure Code [CA1942] 1107
Failure Code [CA1961] 1108
Failure Code [CA1962] 1109
Failure Code [CA2185] 1110
Failure Code [CA2186] 1111
Failure Code [CA2198] 1113
Failure Code [CA2249] 1115
Failure Code [CA2272] 1116
Failure Code [CA2288] 1118
Failure Code [CA2311] 1119
Failure Code [CA2349] 1120
Failure Code [CA2353] 1122
Failure Code [CA2357] 1124
Failure Code [CA2373] 1125
Failure Code [CA2374] 1127
Failure Code [CA2375] 1129
Failure Code [CA2376] 1131
Failure Code [CA2387] 1134
Failure Code [CA2554] 1135
Failure Code [CA2634] 1137
Failure Code [CA2635] 1139
Failure Code [CA2636] 1140
Failure Code [CA2637] 1142
Failure Code [CA2771] 1144
Failure Code [CA2961] 1148
Failure Code [CA2973] 1149
Failure Code [CA2976] 1150
Failure Code [CA3142] 1152
Failure Code [CA3143] 1153
Failure Code [CA3144] 1154
Failure Code [CA3146] 1156
Failure Code [CA3147] 1157
Failure Code [CA3148] 1158
Failure Code [CA3151] 1160
Failure Code [CA3165] 1165
Failure Code [CA3228] 1167
Failure Code [CA3229] 1170
Failure Code [CA3231] 1172
Failure Code [CA3232] 1174
Failure Code [CA3235] 1178
Failure Code [CA3239] 1180
Failure Code [CA3241] 1183
Failure Code [CA3242] 1186
Failure Code [CA3251] 1189
Failure Code [CA3313] 1191
Failure Code [CA3314] 1192
Failure Code [CA3315] 1193
Failure Code [CA3419] 1195
Failure Code [CA3421] 1197
Failure Code [CA3497] 1199
Failure Code [CA3498] 1200
Failure Code [CA3545] 1201
Failure Code [CA3547] 1203
Failure Code [CA3558] 1204
Failure Code [CA3559] 1206
Failure Code [CA3562] 1208
Failure Code [CA3563] 1210
Failure Code [CA3567] 1213
Failure Code [CA3568] 1216
Failure Code [CA3571] 1220
Failure Code [CA3572] 1222
Failure Code [CA3574] 1224
Failure Code [CA3575] 1226
Failure Code [CA3577] 1228
Failure Code [CA3578] 1230
Failure Code [CA3582] 1232
Failure Code [CA3583] 1238
Failure Code [CA3596] 1240
Failure Code [CA3649] 1243
Failure Code [CA3681] 1245
Failure Code [CA3682] 1249
Failure Code [CA3713] 1253
Failure Code [CA3717] 1256
Failure Code [CA3718] 1257
Failure Code [CA3724] 1258
Failure Code [CA3725] 1259
Failure Code [CA3741] 1262
Failure Code [CA3748] 1263
Failure Code [CA3755] 1266
Failure Code [CA3866] 1268
Failure Code [CA3868] 1271
Failure Code [CA4152] 1274
Failure Code [CA4155] 1278
Failure Code [CA4156] 1280
Failure Code [CA4157] 1283
Failure Code [CA4159] 1285
Failure Code [CA4164] 1286
Failure Code [CA4165] 1288
Failure Code [CA4166] 1290
Failure Code [CA4168] 1291
Failure Code [CA4169] 1294
Failure Code [CA4171] 1296
Failure Code [CA4249] 1299
Failure Code [CA4251] 1301
Failure Code [CA4261] 1303
Failure Code [CA4277] 1306
Failure Code [CA4459] 1310
Failure Code [CA4461] 1312
Failure Code [CA4533] 1315
Failure Code [CA4534] 1316
Failure Code [CA4731] 1317
Failure Code [CA4732] 1318
Failure Code [CA4739] 1319
Failure Code [CA4768] 1320
Failure Code [CA4769] 1322
Failure Code [CA4842] 1324
Failure Code [CA4952] 1327
Failure Code [CA5115] 1329
Failure Code [CA5179] 1332
Failure Code [CA5181] 1334
Failure Code [CA5387] 1336
Failure Code [CA5388] 1338
Failure Code [CA5389] 1341
Failure Code [CA5391] 1343
Failure Code [CA5392] 1347
Failure Code [CA5393] 1349
Failure Code [CA5394] 1351
Failure Code [CA5395] 1353
Failure Code [CA5396] 1356
Failure Code [CA5631] 1357
Failure Code [CA5632] 1359
Failure Code [CA5938] 1360
Failure Code [D110KB] 1362
Failure Code [D19JKZ] 1364
Failure Code [D811MC] 1367
Failure Code [D862KA] 1368
Failure Code [D8ALKA] 1370
Failure Code [D8ALKB] 1373
Failure Code [D8AQKR] 1375
Failure Code [D8G1KT] 1382
Failure Code [D8G6KT] 1383
Failure Code [DA20MC] 1384
Failure Code [DA22KK] 1385
Failure Code [DA25KP] 1388
Failure Code [DA29KQ] 1391
Failure Code [DA2LKA] 1393
Failure Code [DA2LKB] 1396
Failure Code [DA2QKR] 1398
Failure Code [DA2RKR] 1407
Failure Code [DAF0KM] 1412
Failure Code [DAF0MB] 1413
Failure Code [DAF0MC] 1414
Failure Code [DAF8KB] 1415
Failure Code [DAF9KQ] 1417
Failure Code [DAFGMC] 1418
Failure Code [DAFLKA] 1419
Failure Code [DAFLKB] 1422
Failure Code [DAFQKR] 1424
Failure Code [DAZ9KQ] 1432
Failure Code [DAZQKR] 1433
Failure Code [DB2QKR] 1440
Failure Code [DB2RKR] 1448
Failure Code [DBP0KM] 1453
Failure Code [DBP0KT] 1454
Failure Code [DBP5KB] 1455
Failure Code [DBP5KY] 1458
Failure Code [DBPQKR] 1461
Failure Code [DDNRKA] 1469
Failure Code [DDNRKY] 1471
Failure Code [DDNS00] 1473
Failure Code [DFB1KZ] 1475
Failure Code [DFB2KZ] 1477
Failure Code [DFB3L8] 1479
Failure Code [DFB4L8] 1481
Failure Code [DFB5KZ] 1483
Failure Code [DFB6KZ] 1485
Failure Code [DGH2KA] 1487
Failure Code [DGH2KB] 1489
Failure Code [DHA4KA] 1491
Failure Code [DHPAMA] 1493
Failure Code [DHPBMA] 1496
Failure Code [DHS3MA] 1499
Failure Code [DHS4MA] 1502
Failure Code [DHS5MA] 1505
Failure Code [DHS8MA] 1507
Failure Code [DHS9MA] 1510
Failure Code [DHSAMA] 1513
Failure Code [DHSBMA] 1516
Failure Code [DHSCMA] 1519
Failure Code [DHSDMA] 1522
Failure Code [DHX1MA] 1525
Failure Code [DKR0MA] 1527
Failure Code [DKULKA] 1530
Failure Code [DKULKB] 1532
Failure Code [DKULKY] 1534
Failure Code [DLM5KA] 1536
Failure Code [DLM5MB] 1538
Failure Code [DR10KA] 1540
Failure Code [DR12KA] 1543
Failure Code [DR20KA] 1545
Failure Code [DR21KX] 1547
Failure Code [DR30KA] 1549
Failure Code [DR31KX] 1551
Failure Code [DR40KA] 1553
Failure Code [DUMBKA] 1555
Failure Code [DUMBKB] 1558
Failure Code [DV20KB] 1560
Failure Code [DW43KA] 1562
Failure Code [DW43KB] 1564
Failure Code [DW43KY] 1566
Failure Code [DW45KA] 1568
Failure Code [DW45KB] 1571
Failure Code [DW45KY] 1574
Failure Code [DW4CKY] 1576
Failure Code [DW91KA] 1578
Failure Code [DW91KB] 1580
Failure Code [DW91KY] 1582
Failure Code [DWA2KA] 1584
Failure Code [DWA2KB] 1586
Failure Code [DWA2KY] 1588
Failure Code [DWJ0KA] 1590
Failure Code [DWJ0KB] 1592
Failure Code [DWJ0KY] 1594
Failure Code [DWK0KA] 1596
Failure Code [DWK0KB] 1598
Failure Code [DWK0KY] 1600
Failure Code [DWK2KA] 1602
Failure Code [DWK2KB] 1604
Failure Code [DWK2KY] 1606
Failure Code [DWN5KA] 1608
Failure Code [DWN5KB] 1610
Failure Code [DWN5KY] 1612
Failure Code [DWNSKA] 1614
Failure Code [DWNSKB] 1616
Failure Code [DWNSKY] 1618
Failure Code [DXA8KA] 1619
Failure Code [DXA8KB] 1621
Failure Code [DXE4KA] 1623
Failure Code [DXE4KB] 1625
Failure Code [DXE4KY] 1627
Failure Code [DXE7KA] 1629
Failure Code [DXE7KB] 1631
Failure Code [DXE7KY] 1633
Failure Code [DXE8KA] 1635
Failure Code [DXE8KB] 1637
Failure Code [DXE8KY] 1639
Failure Code [DXE9KA] 1641
Failure Code [DXE9KB] 1643
Failure Code [DXE9KY] 1645
Failure Code [DXEAKA] 1647
Failure Code [DXEAKB] 1649
Failure Code [DXEAKY] 1651
Failure Code [DY20KA] 1653
Failure Code [DY20MA] 1655
Failure Code [DY2CKB] 1657
Failure Code [DY2DKB] 1660
Failure Code [DY2EKB] 1662
Failure Code [F311KA] 1664
Failure Code [F311KB] 1666
Failure Code [F312KA] 1668
Failure Code [F312KB] 1670
Failure Code [F313KA] 1672
Failure Code [F313KB] 1674
Failure Code [F314KA] 1677
Failure Code [F314KB] 1679
Failure Code [F315KB] 1681
Failure Code [F315KY] 1683
Failure Code [F316KB] 1685
Failure Code [F316KY] 1687
Failure Code [F318KB] 1689
Failure Code [F318KY] 1692
Failure Code [F31AKB] 1694
Failure Code [F31AKY] 1696
Failure Code [F31BKB] 1698
Failure Code [F31BKY] 1700
Failure Code [F31CKB] 1702
Failure Code [F31CKY] 1704
Failure Code [F31DKB] 1706
Failure Code [F31DKY] 1708
Failure Code [F31EKB] 1710
Failure Code [F31EKY] 1712
Troubleshooting of Electrical System (E-Mode) 1714
E-1 Engine Does Not Start (Engine Does Not Crank) 1714
E-2 Manual Preheating System Does Not Operate 1720
E-3 Automatic Preheating System Does Not Operate 1723
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1725
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1727
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1730
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1731
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1732
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1733
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1734
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1735
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1736
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1737
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1738
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1739
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1740
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1741
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1743
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1744
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1745
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1746
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1748
E-23 Some Areas of Machine Monitor Screen are Not Shown 1749
E-24 Function Switch Does Not Operate 1750
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1751
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1752
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1753
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1754
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1755
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1756
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1757
E-32 Alarm Buzzer Cannot be Canceled 1759
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1760
E-34 Service Mode Cannot be Selected 1761
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1762
E-36 All Work Equipment, Swing and Travel Do Not Lock 1765
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1767
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1770
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1772
E-40 One-Touch Power Maximizing Function is Not Cancelled 1775
E-41 Alarm Does Not Sound During Travel 1776
E-42 Alarm Does Not Stop When Machine Stops 1778
E-43 Horn Does Not Sound 1779
E-44 Horn Does Not Stop 1782
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1784
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1785
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1787
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1788
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1789
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1790
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1791
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1792
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1793
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1794
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1795
E-56 Service is Not Shown Correctly with Monitoring Function 1796
E-57 Attachment Hydraulic Circuit Cannot be Changed 1798
E-58 KOMTRAX System Does Not Operate Correctly 1799
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1800
Information Shown in Troubleshooting Table (H-Mode) 1800
Failure Mode and Cause Table 1801
H-1 All Work Equipment, Swing and Travel Do Not Work 1811
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1812
H-3 Fine Control Performance or Response is Unsatisfactory 1814
H-4 Unusual Noise is Heard from Around Hydraulic Pump 1815
H-5 Engine Speed Drops Largely or Engine Stops 1816
H-6 Speed or Power of Boom is Low 1818
H-7 Arm Speed or Power is Low 1821
H-8 Bucket Speed or Power is Low 1825
H-9 Work Equipment Does Not Move in Single Operation 1827
H-10 Hydraulic Drift of Boom is Large 1828
H-11 Hydraulic Drift of Arm is Large 1829
H-12 Hydraulic Drift of Bucket is Large 1831
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1832
H-14 Time Lag of Work Equipment is Large 1833
H-15 One-Touch Power Maximizing Function Does Not Operate 1834
H-16 Attachment Circuit Cannot be Changed 1835
H-17 Oil Flow in Attachment Circuit Cannot be Changed 1836
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1837
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 1838
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1839
H-21 Machine Does Not Travel Straight 1840
H-22 Machine is Not Steered Correctly or Steering Power is Low 1843
H-23 Travel Speed is Low 1845
H-24 One of Tracks Does Not Run 1847
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1848
H-26 Upper Structure Does Not Swing to Right and Left 1849
H-27 Upper Structure Swings Only to Right or Left 1850
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 1851
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 1852
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1853
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1854
H-32 Shock is Large When Upper Structure Stops Swing Operation 1855
H-33 There is Large Unusual Noise When It Stops Swing Operation 1856
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1857
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1858
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1859
H-37 Unusual Noise is Heard from Around Fan 1860
H-38 Quick coupler cylinder will not extend 1861
H-39 Quick coupler cylinder will not retract (but buzzer does not sound) 1863
H-40 Buzzer Does Not Operate (but Quick Coupler Cylinder Does Retract) 1865
H-41 Quick coupler cylinder extends and retracts slowly 1866
Troubleshooting of Engine (S-Mode) 1867
Information Shown in Troubleshooting Table (S-Mode) 1867
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1868
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1869
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1870
S-4 Engine Startability is Unsatisfactory 1872
S-5 Engine Does Not Pick Up Smoothly 1874
S-6 Engine Stops During Operation 1876
S-7 Engine Runs Rough or is Not Stable 1878
S-8 Engine Lacks Power 1879
S-9 Exhaust Smoke is Black 1881
S-10 Engine Oil Consumption is Excessive 1883
S-11 Oil Becomes Dirty Quickly 1884
S-12 Fuel Consumption is Excessive 1885
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1886
S-14 Oil Pressure Drops 1887
S-15 Fuel Mixes Into Engine Oil 1889
S-16 Water Mixes Into Engine Oil (Milky) 1890
S-17 Coolant Temperature Increases Too High (Overheating) 1891
S-18 Unusual Noise is Heard 1892
S-19 Vibration is Excessive 1893
S-20 Air Cannot be Bled from Fuel Circuit 1894
S-21 Active Regeneration is Done Frequently 1895
S-22 Active Regeneration Continues Long 1896
S-23 White Smoke is Exhausted During Active Regeneration 1897
S-24 DEF Consumption is Excessive 1898
S-25 There is Unusual Smell (Irritating Odor) 1900
S-26 Foreign Materials Enter DEF (DEF Increases) 1901
50 Disassembly and Assembly 1903
Table of Contents 1904
Precautions Before Work 1909
Related Information on Disassembly and Assembly 1910
How to Read This Manual 1910
Coating Materials List 1912
Special Tool List 1917
Sketches of Special Tools 1931
Engine and Cooling System 1939
Remove and Install Supply Pump Assembly 1939
How to Remove Supply Pump Assembly 1939
How to Install Supply Pump Assembly 1943
Remove and Install Injector Assembly 1947
How to Remove Injector Assembly 1947
How to Install Injector Assembly 1950
Remove and Install Cylinder Head Assembly 1956
How to Remove Cylinder Head Assembly 1956
How to Install Cylinder Head Assembly 1966
Remove and Install EGR Valve Assembly 1983
How to Remove EGR Valve Assembly 1983
How to Install EGR Valve Assembly 1984
Remove and Install EGR Cooler Assembly 1986
How to Remove EGR Cooler Assembly 1986
How to Install EGR Cooler Assembly 1988
Remove and Install Starter Assembly 1991
How to Remove Starting Motor Assembly 1991
How to Install Starting Motor Assembly 1993
Remove and Install Alternator Belt 1996
How to Remove Alternator Belt 1996
How to Install Alternator Belt 1998
Remove and Install Radiator Assembly 2001
How to Remove Radiator Assembly 2001
How to Install Radiator Assembly 2005
Remove and Install Hydraulic Oil Cooler Assembly 2009
How to Remove Hydraulic Oil Cooler Assembly 2009
How to Install Hydraulic Oil Cooler Assembly 2013
Remove and Install Aftercooler Assembly 2017
How to Remove Aftercooler Assembly 2017
How to Install Aftercooler Assembly 2019
Remove and Install Fan Clutch Assembly 2022
How to Remove Fan Clutch Assembly 2022
How to Install Fan Clutch Assembly 2026
Remove and Install Fan 2030
How to Remove Fan 2030
How to Install Fan 2030
Remove and Install Engine and Main Pump Assembly 2031
How to Remove Engine and Main Pump Assembly 2031
How to Install Engine and Main Pump Assembly 2047
Remove and Install Engine Front Oil Seal 2064
How to Remove Engine Front Oil Seal 2064
How to Install Engine Front Oil Seal 2068
Remove and Install Engine Rear Oil Seal 2074
How to Remove Engine Rear Oil Seal 2074
How to Install Engine Rear Oil Seal 2075
Remove and Install Fuel Cooler Assembly 2078
How to Remove Fuel Cooler Assembly 2078
How to Install Fuel Cooler Assembly 2080
Remove and Install Engine Hood Assembly 2083
How to Remove Engine Hood Assembly 2083
How to Install Engine Hood Assembly 2085
Remove and Install KDOC Assembly 2091
How to Remove KDOC Assembly 2091
How to Install KDOC Assembly 2094
Remove and Install KDOC and SCR Assembly 2097
How to Remove KDOC and SCR Assembly 2097
How to Install KDOC and SCR Assembly 2104
Remove and Install Bellows Pipe Assembly 2111
How to Remove Bellows Pipe Assembly 2111
How to Install Bellows Pipe Assembly 2113
Remove and Install Fuel Tank Assembly 2118
How to Remove Fuel Tank Assembly 2118
How to Install Fuel Tank Assembly 2123
Remove and Install DEF Tank Assembly 2129
How to Remove DEF Tank Assembly 2129
How to Install DEF Tank Assembly 2137
Remove and Install DEF Tank Sensor Flange Assembly 2143
How to Remove DEF Tank Sensor Flange Assembly 2143
How to Install DEF Tank Sensor Flange Assembly 2144
Remove and Install DEF Tank Sensor 2146
How to Remove DEF Tank Sensor 2146
How to Install DEF Tank Sensor 2147
Remove and Install DEF Tank Strainer 2149
How to Remove DEF Tank Strainer 2149
How to Install DEF Tank Strainer 2149
Remove and Install DEF Tank Filler Port Filter 2150
How to Remove DEF Tank Filler Port Filter 2150
How to Install DEF Tank Filler Port Filter 2152
Remove and Install SCR Assembly 2155
How to Remove SCR Assembly 2155
How to Install SCR Assembly 2157
Remove and Install KCCV Assembly 2159
How to Remove KCCV Assembly 2159
How to Install KCCV Assembly 2160
Remove and Install DEF Mixing Tube 2162
How to Remove DEF Mixing Tube 2162
How to Install DEF Mixing Tube 2169
Remove and Install DEF Injector 2175
How to Remove DEF Injector 2175
How to Install DEF Injector 2178
Remove and Install DEF Pump 2181
How to Remove DEF Pump 2181
How to Install DEF Pump 2184
Remove and Install DEF Hose 2187
How to Remove DEF Hose 2187
How to Install DEF Hose 2197
Remove and Install Air Cleaner Assembly 2207
How to Remove Air Cleaner Assembly 2207
How to Install Air Cleaner Assembly 2208
Remove and Install Air Conditioner Compressor Assembly 2211
How to Remove Air Conditioner Compressor Assembly 2211
How to Install Air Conditioner Compressor Assembly 2213
Remove and Install Air Conditioner Condenser Assembly 2216
How to Remove Air Conditioner Condenser Assembly 2216
How to Install Air Conditioner Condenser Assembly 2217
Power Train 2219
Remove and Install Travel Motor and Final Drive Assembly 2219
How to Remove Travel Motor and Final Drive Assembly 2219
How to Install Travel Motor and Final Drive Assembly 2220
Disassemble and Assemble Final Drive Assembly 2221
How to Disassemble Final Drive Assembly 2222
How to Assemble Final Drive Assembly 2225
Remove and Install Swing Motor and Swing Machinery Assembly 2233
How to Remove Swing Motor and Swing Machinery Assembly 2233
How to Install Swing Motor and Swing Machinery Assembly 2235
Disassemble and Assemble Swing Machinery Assembly 2237
How to Disassemble Swing Machinery Assembly 2237
How to Assemble Swing Machinery Assembly 2241
Remove and Install Swing Circle Assembly 2248
How to Remove Swing Circle Assembly 2248
How to Install Swing Circle Assembly 2248
Undercarriage and Frame 2250
Separate and Connect Track Assembly 2250
How to Separate Track Assembly 2250
How to Install Track Assembly 2251
Remove and Install Sprocket 2254
How to Remove Sprocket 2254
How to Install Sprocket 2255
Remove and Install Idler and Idler Cushion Assembly 2256
How to Remove Idler and Idler Cushion Assembly 2256
How to Install Idler and Idler Cushion Assembly 2257
Disassemble and Assemble Idler Assembly 2258
How to Disassemble Idler Assembly 2258
How to Assemble Idler Assembly 2259
Disassemble and Assemble Idler Cushion Assembly 2263
How to Disassemble Idler Cushion Assembly 2263
How to Assemble Idler Cushion Assembly 2264
Disassemble and Assemble Track Roller Assembly 2266
How to Disassemble Track Roller Assembly 2266
How to Assemble Track Roller Assembly 2267
Disassemble and Assemble Carrier Roller Assembly 2270
How to Disassemble Carrier Roller Assembly 2270
How to Assemble Carrier Roller Assembly 2272
Remove and Install Revolving Frame Assembly 2274
How to Remove Revolving Frame Assembly 2274
How to Install Revolving Frame Assembly 2277
Remove and Install Counterweight Assembly 2280
How to Remove Counterweight Assembly 2280
How to Install Counterweight Assembly 2281
Hydraulic System 2284
Remove and Install Center Swivel Joint Assembly 2284
How to Remove Center Swivel Joint Assembly 2284
How to Install Center Swivel Joint Assembly 2287
Disassemble and Assemble Center Swivel Joint Assembly 2290
How to Disassemble Center Swivel Joint Assembly 2290
How to Assemble Center Swivel Joint Assembly 2291
Remove and Install Hydraulic Tank Assembly 2293
How to Remove Hydraulic Tank Assembly 2293
How to Install Hydraulic Tank Assembly 2300
Remove and Install Main Pump Assembly 2308
How to Remove Main Pump Assembly 2308
How to Install Main Pump Assembly 2310
Remove and Install Control Valve Assembly 2313
How to Remove Control Valve Assembly 2313
How to Install Control Valve Assembly 2316
Disassemble and Assemble Control Valve Assembly 2320
How to Assemble Control Valve Assembly 2320
How to Replace Pressure Reducing Valve Cartridge Assembly 2322
Disassemble and Assemble Work Equipment PPC Valve Assembly 2325
How to Disassemble Work Equipment PPC Valve Assembly 2325
How to Assemble Work Equipment PPC Valve Assembly 2326
Work Equipment 2328
Remove and Install Work Equipment Assembly 2328
How to Remove Work Equipment Assembly 2328
How to Install Work Equipment Assembly 2331
Remove and Install Boom Anti-drop Valve Assembly 2335
How to Remove Boom Anti-drop Valve Assembly 2335
How to Install Boom Anti-drop Valve Assembly 2337
Remove and Install Arm Anti-Drop Valve Assembly 2338
How to Remove Arm Anti-Drop Valve Assembly 2338
How to Install Arm Anti-Drop Valve Assembly 2340
Disassemble and Assemble Anti-Drop Valve Assembly 2341
How to Disassemble Anti-Drop Valve Assembly 2341
How to Assemble Anti-Drop Valve Assembly 2341
Disassemble and Assemble Work Equipment Cylinder Assembly 2342
How to Disassemble Work Equipment Cylinder Assembly 2343
How to Assemble Work Equipment Cylinder Assembly 2345
CAB Related Parts 2351
Remove and Install Operator Cab Assembly 2351
How to Remove Operator Cab Assembly 2351
How to Install Operator Cab Assembly 2358
Remove and Install Operator Cab Glass (Adhered Glass) 2366
How to Remove Operator Cab Glass (Adhered Glass) 2368
How to Install Operator Cab Glass (Adhered Glass) 2368
Remove and Install Front Window Assembly 2378
How to Remove Front Window Assembly 2378
How to Install Front Window Assembly 2381
Remove and Install Floor Frame Assembly 2387
How to Remove Floor Frame Assembly 2387
How to Install Floor Frame Assembly 2391
Remove and Install Air Conditioner Unit Assembly 2396
How to Remove Air Conditioner Unit Assembly 2396
How to Install Air Conditioner Unit Assembly 2400
Remove and Install Operator Seat 2406
How to Remove Operator Seat 2406
How to Install Operator Seat 2408
How to Remove and Install Seat Belt 2411
How to Remove Seat Belt 2411
How to Install Seatbelt 2411
Remove and Install Work Equipment Control Lever Assembly 2413
How to Remove Work Equipment Control Lever Assembly 2413
How to Install Work Equipment Control Lever Assembly 2419
Remove and Install Front Wiper Assembly 2428
How to Remove Front Wiper Assembly 2428
How to Install Front Wiper Assembly 2433
Electrical System 2442
Remove and Install Engine Controller Assembly 2442
How to Remove Engine Controller Assembly 2442
How to Install Engine Controller Assembly 2444
Remove and Install Pump Controller Assembly 2447
How to Remove Pump Controller Assembly 2447
How to Install Pump Controller Assembly 2450
Remove and Install KomVision Controller Assembly 2453
How to Remove KomVision Controller Assembly 2453
How to Install KomVision Controller Assembly 2454
Remove and Install Machine Monitor Assembly 2456
How to Remove Machine Monitor Assembly 2456
How to Install Machine Monitor Assembly 2458
Remove and Install Pump Swash Plate Sensor 2462
How to Remove Pump Swash Plate Sensor 2462
How to Install Pump Swash Plate Sensor 2462
Remove and Install Mass Air Flow and Temperature Sensor 2464
How to Remove Mass Air Flow and Temperature Sensor 2464
How to Install Mass Air Flow and Temperature Sensor 2465
Remove and Install KCCV Crankcase Pressure Sensor 2467
How to Remove KCCV Crankcase Pressure Sensor 2467
How to Install KCCV Crankcase Pressure Sensor 2468
Remove and Install SCR Temperature Sensor 2470
How to Remove SCR Temperature Sensor 2470
How to Install SCR Temperature Sensor 2471
Remove and Install KomVision Camera 2473
How to Remove KomVision Camera 2473
How to Install KomVision Camera 2474
Remove and Install Gateway Function Controller Assembly 2476
How to Remove Gateway Function Controller Assembly 2476
How to Install Gateway Function Controller Assembly 2481
Remove and Install Communication Terminal Wiring Harness 2486
How to Remove Communication Terminal Wiring Harness 2486
How to Install Communication Terminal Wiring Harness 2494
Remove and Install Communication Terminal 2503
How to Remove Communication Terminal 2503
How to Install Communication Terminal 2505
60 Maintenance Standard 2509
Table of Contents 2510
Engine and Cooling System 2511
Maintenance Standard for Engine Mount 2511
Maintenance Standard for Cooling System 2512
Power Train 2514
Maintenance Standard for Swing Circle 2514
Maintenance Standard for Swing Machinery 2515
Maintenance Standard for Final Drive 2517
Maintenance Standard for Sprocket 2519
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2520
Undercarriage and Frame 2521
Maintenance Standard for Track Frame and Idler Cushion 2521
Maintenance Standard for Idler 2523
Maintenance Standard for Track Roller 2525
Maintenance Standard for Carrier Roller 2526
Maintenance Standard for Track Shoes 2527
Maintenance Standard for Triple Shoes 2530
Hydraulic System 2531
Maintenance Standard for Hydraulic Tank 2531
Maintenance Standard for Main Pump 2532
Maintenance Standard for PC-EPC Valve 2534
Maintenance Standard for Travel Motor 2535
Maintenance Standard for Control Valve 2538
Maintenance Standard for Boom Anti-Drop Valve 2549
Maintenance Standard for Arm Anti-Drop Valve 2551
Maintenance Standard for Work Equipment and Swing PPC Valve 2553
Maintenance Standard for Travel PPC Valve 2556
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2559
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2560
Maintenance Standard for 2nd-Line Attachment PPC Valve 2562
Maintenance Standard for Solenoid Valve 2564
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2565
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2566
Maintenance Standard for Center Swivel Joint 2567
Work Equipment 2568
Maintenance Standard for Work Equipment Linkage 2568
Dimensions of Arm 2573
Dimensions of Bucket 2575
Maintenance Standard for Boom Cylinder 2577
Maintenance Standard for Arm Cylinder 2578
Maintenance Standard for Bucket Cylinder 2579
80 Appendix 2581
Table of Contents 2582
Precautions Before Work 2584
Air Conditioner System 2585
Precautions for Refrigerant 2585
Air Conditioner Component 2586
Specifications of Air Conditioner 2588
Structure and Function of Refrigeration Cycle 2589
Outline of Refrigeration Cycle 2590
Component Parts of Air Conditioner System 2592
Air Conditioner Unit 2592
Configuration Diagram of Air Conditioner Unit 2592
Function of Air Conditioner Unit 2594
Component Parts of Air Conditioner Unit 2596
Function of Evaporator as Air Conditioner Unit Component 2597
Function of Heater Core as Air Conditioner Unit Component 2597
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2597
Function of Servo Motor as Air Conditioner Unit Component 2597
Structure of Expansion Valve as Air Conditioner Unit Component 2598
Function of Expansion Valve as Air Conditioner Unit Component 2598
Operate Expansion Valve as Air Conditioner Unit Component 2598
Function of Dual Pressure Switch 2599
Air Conditioner Controller 2600
Structure of Air Conditioner Controller 2600
Compressor 2601
Structure of Compressor 2601
Specifications of Compressor 2601
Function of Compressor 2601
Condenser 2602
Structure of Condenser 2602
Specifications of Condenser 2602
Function of Condenser 2602
Air Conditioner Related Sensors 2604
Structure of Sunlight Sensor 2604
Function of Sunlight Sensor 2604
Structure of Outside Temperature Sensor 2604
Function of Outside Air Temperature Sensor 2604
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2606
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2608
System Diagram of Air Conditioner 2610
Input and Output Signals of Air Conditioner Controller 2611
Function of Air Conditioner Controller 2612
Locations of Air Conditioner Parts and Layout of Connectors 2613
Examine Air Leakage (Duct) 2617
How to Examine Air Leakage (Duct) 2617
Examine Air Conditioner with Self-Diagnosis Function 2619
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2620
Examine Vent (Mode) Changeover 2621
How to Examine Vent (Mode) Changeover 2621
Examine Fresh/Recirc Air Changeover 2623
How to Examine Fresh/Recirc Air Changeover 2623
Examine Sunlight Sensor 2624
How to Examine Sunlight Sensor 2624
Examine Refrigerant (Dual) Pressure Switch 2625
How to Examine Refrigerant (Dual) Pressure Switch 2625
Examine Relay 2626
How to Examine Relay 2626
Air Conditioner Troubleshooting Chart 1 2627
Air Conditioner Troubleshooting Chart 2 2628
Information Shown in Troubleshooting Table 2631
Failure Code [879AKA] 2632
Failure Code [879AKB] 2633
Failure Code [879BKA] 2634
Failure Code [879BKB] 2636
Failure Code [879CKA] 2638
Failure Code [879CKB] 2639
Failure Code [879DKZ] 2640
Failure Code [879EMC] 2642
Failure Code [879FMC] 2643
Failure Code [879GKX] 2644
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2646
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2648
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2651
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2653
Troubleshooting by Gauge Pressure 2655
Connect Service Tool 2658
How to Connect Service Tool 2658
Precautions for Disconnection and Connection of Air Conditioner Piping 2660
Handle Compressor Oil 2662
How to Replace Desiccant 2664
90 Circuit Diagrams 2667
Table of Contents 2668
Hydraulic Circuit Diagram 2669
Symbols Used in Hydraulic Circuit Diagram 2669
Hydraulic Circuit Diagram (1/2) 2673
Hydraulic Circuit Diagram (2/2) 2675
Electrical Circuit Diagram 2677
Symbols Used in Electric Circuit Diagram 2677
Electrical Circuit Diagram (1/9) 2681
Electrical Circuit Diagram (2/9) 2683
Electrical Circuit Diagram (3/9) 2685
Electrical Circuit Diagram (4/9) 2687
Electrical Circuit Diagram (5/9) 2689
Electrical Circuit Diagram (6/9) 2691
Electrical Circuit Diagram (7/9) 2693
Electrical Circuit Diagram (8/9) 2695
Electrical Circuit Diagram (9/9) 2697
Index 2699

IMAGES PREVIEW OF THE MANUAL:

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