Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06734-11 PDF

Description

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06734-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06734-11 – PDF DOWNLOAD 

Language : English
Pages : 2960
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06734-11 – PDF DOWNLOAD 

SERIAL NUMBERS 500001 and up

Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

TABLE OF CONTENTS:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06734-11 – PDF DOWNLOAD 

SERIAL NUMBERS 500001 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 When You Discard Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions When You Add 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
Disconnect and Connect Connector with Lock to Pull 66
Disconnect and Connect Connector with Lock to Push 67
Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
01 Specification 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: PC210LC-11 91
Working Range Drawings 93
Working Range: PC210LC-11 93
Specifications 94
Specifications: PC210LC-11 94
Weight Table 97
Weight Table: PC210LC-11 97
Table of Fuel, Coolant, and Lubricants 99
Fuel, Coolant, Lubricant 100
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 100
10 Structure and Function 103
Table of Contents 104
Urea SCR System 108
Layout Drawing of Urea SCR System 109
Urea SCR System Diagram 114
Function of Urea SCR System 115
Function of DEF System 115
Inducement Strategy 117
Component Parts of Urea SCR System 131
DEF Mixing Tube 131
SCR Assembly 132
DEF Tank 134
DEF Pump 136
DEF Injector 137
DEF Hose 138
DEF Tank Heating Valve 139
Boot-up System 140
Layout Drawing of Boot-up System 140
System Operating Lamp System 142
System Diagram of System Operating Lamp System 142
Function of Operation Lamp System 142
Operation of System Operating Lamp System 142
Battery Disconnect Switch 143
Function of Battery Disconnect Switch 143
Engine System 144
Layout Drawing of Engine System 144
Specifications of Engine System 145
Function of Engine System 145
Engine Control System 146
System Diagram of Engine Control 146
Operation of Engine Control System 147
Auto-Deceleration System 149
System Diagram of Auto-Deceleration System 149
Function of Auto-Deceleration System 149
Operation of Auto-Deceleration System 150
Engine Automatic Warm-up System 151
System Diagram of Engine Automatic Warm-up System 151
Function of Engine Automatic Warm-up System 152
Overheat Prevention System 153
Overheat Prevention System Diagram 153
Function of Overheat Prevention System 154
Turbocharger Protection System 156
System Diagram of Turbocharger Protection System 156
Function of Turbocharger Protection System 157
Automatic Idle Stop System 158
System Diagram of Automatic Idle Stop System 158
Function of Automatic Idle Stop System 158
Operation of Automatic Idle Stop System 158
Component Parts of Engine System 161
VGT 161
EGR System 166
EGR Valve 168
EGR Cooler 170
KCCV System 172
KCCV Ventilator 174
KDPF 176
Cooling System 180
Layout Drawing of Cooling System 180
Specifications of Cooling System 181
Fan Speed Control System of Fan Clutch 182
Fan Speed Control System Diagram of Fan Clutch 182
Function of Fan Speed Control System of Fan Clutch 183
Engine Output Control System of Fan Clutch 184
Engine Output Control System Diagram of Fan Clutch 184
Function of Engine Output Control System of Fan Clutch 184
Component Parts of Cooling System 186
Fan Clutch 186
Control System 187
Layout Drawing of Control System 187
Machine Monitor System 190
System Diagram of Machine Monitor System 190
Function of Machine Monitor System 191
KomVision System 192
Layout Drawing of KomVision System 192
System Diagram of KomVision System 194
Function of KomVision System 194
KOMTRAX System 196
System Diagram of KOMTRAX System 196
Function of KOMTRAX System 196
Component Parts of Control System 197
Machine Monitor 197
KomVision Controller 212
KomVision Camera 216
Gateway Function Controller 217
Communication Terminal 220
Pump Controller 222
Resistor for PC-EPC Valve 226
CAN Terminating Resistor 227
Engine Controller 228
Fuel Control Dial 235
Hydraulic System 237
Layout Drawing of Hydraulic System 237
CLSS 243
Structure of CLSS 243
Operation of Unload Valve and LS Pressure 245
Pump Swash Plate Angle (Oil Flow) Control 246
Pressure Compensation Control 262
Engine and Pump Combined Control System 265
Engine and Pump Combined Control System Diagram 265
Function of Engine and Pump Combined Control System 266
Pump and Valve Control System 271
Pump and Valve Control System Diagram 271
Function of Pump and Valve Control System 272
Component Parts of Hydraulic System 274
Hydraulic Tank 274
Main Pump 276
Control Valve 302
Work Equipment System 361
Layout Drawing of Work Equipment System 361
Structure of Valve Control 366
One-Touch Power Maximizing System 368
System Diagram of One-Touch Power Maximizing System 368
Function of One-Touch Power Maximizing System 369
PPC Lock System 370
System Diagram of PPC Lock 370
Function of PPC Lock System 370
Work Equipment and Travel Automatic Lock System 371
System Diagram of Lock Lever Automatic Lock System 371
Function of Work Equipment and Travel Automatic Lock System 371
Operation of Lock Lever Automatic Lock System 372
Attachment Oil Flow Adjuster System 373
Attachment Oil Flow Adjuster System Diagram 373
Function of Attachment Oil Flow Adjuster System 374
Tool Control System 375
Tool Control System Diagram 375
Component Parts of Work Equipment System 377
Work Equipment and Swing PPC Valve 377
1st-Line Attachment PPC Valve (with EPC Valve) 384
2nd-Line Attachment PPC Valve 392
Solenoid Valve 394
Boom Anti-drop Valve 397
Arm Anti-Drop Valve 401
Attachment Circuit Selector Valve (For High Pressure) 406
Attachment Circuit Selector Valve (For Low Pressure) 408
1st-Line Attachment Variable Relief Valve 409
2nd-Line Attachment Variable Relief Valve 412
Attachment Bypass Solenoid Valve 415
Pilot Circuit Accumulator 417
Attachment Circuit Accumulator 418
Swing System 419
Layout Drawing of Swing System 419
Swing Control System Diagram 423
Function of Swing Control System 423
Component Parts of Swing System 427
Swing Motor 427
Swing Machinery 439
Swing Circle 441
Travel System 442
Layout Drawing of Travel System 442
System Diagram of Travel Control System 446
Function of Travel Control System 447
Component Parts of Travel System 448
Travel Motor 448
Final Drive 460
Travel PPC Valve 463
Center Swivel Joint 467
Undercarriage and Frame 469
Layout Drawing of Undercarriage 469
Specifications of Undercarriage 470
Work Equipment 471
Structure of Work Equipment 471
Function of Work Equipment 471
Work Equipment Clearance Adjustment Shim 472
Function of Work Equipment Clearance Adjustment Shim 472
Bucket Clearance Adjustment Shim 472
Function of Bucket Clearance Adjustment Shim 472
CAB Related Parts 473
ROPS CAB 473
Structure of ROPS CAB 473
Function of ROPS CAB 473
CAB Mount 474
Structure of CAB Mount 474
Function of CAB Mount 474
CAB Tipping Stopper 475
Structure of CAB Tipping Stopper 475
Function of CAB Tipping Stopper 475
20 Standard Value Table 477
Table of Contents 478
Standard Value Table for Engine 479
Standard Value Table for Engine: PC210LC-11 479
Standard Value Table for Machine 483
Standard Value Table for Machine: PC210LC-11 483
Machine Posture and Procedures to Measure Performance 496
Standard Value Table for Electricity 500
Standard Value Table for Electricity 500
30 Testing and Adjusting 511
Table of Contents 512
Precautions Before Work 515
Related Information on Testing and Adjusting 516
Tools for Testing and Adjusting 516
Sketch of Tools for Testing and Adjusting 523
Engine and Cooling System 525
Examine Engine Speed 525
How to Examine Engine Speed 525
Examine Boost Pressure 528
How to Examine Boost Pressure on Machine Monitor 528
How to Examine Boost Pressure by Testing Tool 529
Examine Exhaust Gas Color 530
How to Examine Exhaust Gas Color with the Handy Smoke Checker 530
How to Examine Exhaust Gas Color with Smoke Meter 531
Examine Mass Air Flow and Temperature Sensor 533
How to Examine Mass Air Flow and Temperature Sensor 533
Examine and Adjust Valve Clearance 535
Check Valve Clearance 535
Adjust Valve Clearance 536
Examine Compression Pressure 538
How to Examine Compression Pressure 538
Examine Blowby Pressure 543
How to Examine Blowby Pressure 543
Examine Engine Oil Pressure 545
How to Examine Engine Oil Pressure 545
Examine EGR Valve and VGT Oil Pressure 546
How to Examine EGR Valve and VGT Oil Pressure 546
Examine Fuel Pressure 548
How to Examine Fuel Pressure 549
Examine Fuel Discharge, Return and Leakage 554
How to Examine Fuel Discharge, Return, and Leakage 555
Bleed Air from Fuel System 561
How to Bleed Air from Fuel System 561
Examine Fuel Circuit for Leakage 562
How to Examine Fuel System for Leakage 562
Handle Cylinder Cut-out Mode Operation 564
Handle No-Injection Cranking Operation 565
Examine and Adjust Air Conditioner Compressor Belt Tension 566
How to Examine Air Conditioner Compressor Belt 566
How to Adjust Air Conditioner Compressor Belt 566
Examine Fan Belt and Alternator Belt 568
How to Examine Fan Belt and Alternator Belt 568
Examine Automatic Tensioner 569
How to Examine Automatic Tensioner 569
Examine Cooling Fan Speed 570
How to Examine Cooling Fan Speed 570
Write Correction for Ash in Soot Accumulation to Engine Controller 571
How to Write Correction for Ash in Soot Accumulation to Engine Controller 571
Examine SCR Related Functions 572
Examine DEF Pump Raised Pressure 576
Examine Injection Volume from DEF Injector 579
Examine DEF Line Heater Relay 1 584
Examine DEF Line Heater Relay 2 587
Examine DEF Pump Heater Relay 590
Examine DEF Tank Heater Valve 593
Examine SCR Denitration Efficiency 596
Clean DEF Tank 600
How to Clean DEF Tank 600
Clean DEF Pump 604
How to Clean DEF Pump 604
Bleed Air from Coolant Circuit of DEF Tank 611
How to Bleed Air from Coolant Circuit of DEF Tank 611
Power Train 613
Examine Swing Circle Bearing Clearance 613
How to Examine Swing Circle Bearing Clearance 613
Undercarriage and Frame 614
Examine and Adjust Track Tension 614
How to Examine Track Tension 614
How to Adjust Track Tension 614
Hydraulic System 616
Release Remained Pressure in Hydraulic Circuit 616
How to Release Remained Pressure in Hydraulic System 616
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 617
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 618
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 624
Examine Oil Pressure of Control Circuit 627
Examine Oil Pressure in Control Circuit 627
Examine and adjust oil pressure in pump PC control circuit 629
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 629
Examine PC-EPC Valve Outlet Pressure 630
How to Adjust Oil Pressure in Pump PC Control Circuit 631
Examine and Adjust Oil Pressure in Pump LS Control Circuit 633
Examine LS Differential Pressure with Machine Monitor 633
Examine LS Differential Pressure by Testing Tool 634
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 637
How to Examine LS-EPC Valve Outlet Pressure 638
Adjust LS Valve 639
Examine Outlet Pressure of Solenoid Valve 640
How to Examine Outlet Pressure of Solenoid Valve 640
Operating Condition of Solenoid Valve 641
Examine PPC Valve Outlet Pressure 644
Examine Outlet Pressure in PPC Valve 644
Examine Attachment Circuit Oil Pressure 646
How to Examine Attachment Circuit Oil Pressure 646
Adjust Play of Work Equipment and Swing PPC Valves 647
How to Adjust Play of Work Equipment and Swing PPC Valves 647
Examine Pump Swash Plate Sensor 648
How to Examine pump swash plate sensor 648
Examine Parts Which Cause Hydraulic Drift of Work Equipment 649
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 649
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 649
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 650
Examine Oil Leakage 651
How to Examine Oil Leakage from Boom Cylinder 651
How to Examine Oil Leakage from Arm Cylinder 651
How to Examine Oil Leakage from Bucket Cylinder 652
How to Examine Oil Leakage from Swing Motor 653
How to Examine Oil Leakage from Travel Motor 653
Bleed Air from Hydraulic System 654
How to Bleed Air from Hydraulic System 656
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 658
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 658
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 662
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 662
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 666
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 666
CAB Related Parts 673
Examine CAB Tipping Stopper 673
How to Examine Cab Tipping Stopper 673
How to Adjust Mirrors 674
Procedure to Adjust Machine Left Front Mirror (A) 674
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 675
Procedure to Adjust Machine Right Front Mirror (B) 676
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 677
Procedure to Adjust Machine Right Side Mirror (C) 678
Electrical System 680
Set and Operate Machine Monitor 680
Operator Mode 684
Function to Show Technician Identification Status Screen 684
Function to Show Operator Identification Input Screen 684
Examine Function by LCD (Liquid Crystal Display) 685
Examine Function of Service Meter 685
Usage Limitation and Maintenance Password Change Function 685
Service Mode 688
How to See Pre-defined Monitoring Information 690
How to Examine Self-Define Monitor Information 697
Abnormality Record Menu 708
How to See Maintenance Record 712
Maintenance Mode Setting 713
Set Phone Number Entry 717
Default Menu 719
Diagnostic Tests Menu 731
Adjustment Menu 740
No-Injection Cranking Operation 767
KOMTRAX Settings Menu 769
Show Service Message 771
Start Up KOMTRAX System 773
Adjust Rearview Camera Angle 778
How to Adjust Rearview Camera Angle 778
Adjust KomVision Camera Angle 781
Adjust KomVision Related Function 783
Setting of KomVision (Main Setting) 783
Setting of KomVision (Camera Setting) 785
Setting of KomVision (Camera Calibration) 787
KomVision screen – Check 12 m visibility 800
Set Region of Bluetooth(R) Compatible Radio 803
Set Region of Bluetooth(R) Compatible Radio 803
Handle Voltage Circuit of Engine Controller 805
Handle Battery Disconnect Switch 806
Examine Diodes 807
Examine Diodes by Digital Tester 807
How to Examine Diodes by Analog Tester 807
Pm Clinic 808
Pm Clinic Service 808
Pm Clinic Check Sheet 810
40 Troubleshooting 823
Table of Contents 824
Precautions Before Work 835
Related Information to Troubleshooting 836
General Troubleshooting Points 836
Troubleshooting Points for Urea SCR System 837
Sequence of Events in Troubleshooting 851
Checks Before Troubleshooting 853
Inspection Procedure Before Troubleshooting 855
Walk-Around Check 855
Test in Accordance with Testing Procedure 857
Examine Fuel Level and Type 857
Examine for Impure Ingredient in Fuel 857
Examine Fuel Prefilter 858
Examine Water Separator, Drain Water and Sediment 858
How to Replace Fuel Prefilter Cartridge 859
Examine Fuel Main Filter 860
Examine Engine Oil Level (Oil Quantity in Oil Pan) 862
Examine Coolant Level (Reservoir Tank) 863
Examine Air Cleaner Clogging 863
Clean Outer Element 864
Replace Element 866
Examine Hydraulic Oil Level 867
Examine Hydraulic Oil Strainer 868
Examine Hydraulic Oil Filter 869
Examine Oil Level in Swing Machinery Case 870
Examine Oil Level in Damper Case 871
Examine Oil Level in Final Drive Case 871
Bleed Air from Fuel System 872
Bleed Air from Hydraulic System 872
How to Examine Electric Equipment 872
Preparation for Troubleshooting of Electrical System 880
Procedure for Troubleshooting 893
Symptom and Troubleshooting Numbers 896
Information Shown in Troubleshooting Table 900
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 902
Connector List and Layout (Halogen lamp Specifications) 905
Connector List and Layout (LED lamp Specifications) 918
Connector Contact Connection Table 932
T-Branch Box and T-Branch Adapter Table 972
Fuse Location Table 978
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 981
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 985
Failure Code Table 987
Troubleshooting by Failure Code (Display of Code) 1006
Failure Code [6AZ0ZG] 1006
Failure Code [879AKA] 1008
Failure Code [879AKB] 1009
Failure Code [879BKA] 1010
Failure Code [879BKB] 1012
Failure Code [879CKA] 1014
Failure Code [879CKB] 1015
Failure Code [879DKZ] 1016
Failure Code [879EMC] 1018
Failure Code [879FMC] 1019
Failure Code [879GKX] 1020
Failure Code [989L00] 1022
Failure Code [989M00] 1023
Failure Code [989N00] 1024
Failure Code [A1U0N3] 1025
Failure Code [A1U0N4] 1027
Failure Code [A900FR] 1029
Failure Code [A900N6] 1030
Failure Code [A900NY] 1031
Failure Code [AA10NX] 1032
Failure Code [AB00KE] 1034
Failure Code [AQ10N3] 1037
Failure Code [AS00N3] 1039
Failure Code [AS00R2] 1041
Failure Code [AS00R3] 1042
Failure Code [AS00R4] 1043
Failure Code [AS00R5] 1044
Failure Code [AS00R6] 1045
Failure Code [AS00ZK] 1046
Failure Code [AS10KM] 1047
Failure Code [AS10NR] 1048
Failure Code [AS10NT] 1049
Failure Code [B@BAZG] 1050
Failure Code [B@BAZK] 1051
Failure Code [B@BCNS] 1053
Failure Code [B@BCQA] 1054
Failure Code [B@BCZK] 1056
Failure Code [B@HANS] 1058
Failure Code [CA115] 1059
Failure Code [CA122] 1060
Failure Code [CA123] 1062
Failure Code [CA131] 1064
Failure Code [CA132] 1066
Failure Code [CA144] 1068
Failure Code [CA145] 1070
Failure Code [CA153] 1072
Failure Code [CA154] 1075
Failure Code [CA187] 1077
Failure Code [CA221] 1079
Failure Code [CA222] 1081
Failure Code [CA227] 1083
Failure Code [CA234] 1084
Failure Code [CA238] 1085
Failure Code [CA239] 1087
Failure Code [CA249] 1089
Failure Code [CA256] 1091
Failure Code [CA271] 1093
Failure Code [CA272] 1095
Failure Code [CA322] 1097
Failure Code [CA323] 1099
Failure Code [CA324] 1101
Failure Code [CA325] 1103
Failure Code [CA331] 1105
Failure Code [CA332] 1107
Failure Code [CA343] 1109
Failure Code [CA351] 1110
Failure Code [CA352] 1111
Failure Code [CA356] 1114
Failure Code [CA357] 1116
Failure Code [CA386] 1118
Failure Code [CA428] 1119
Failure Code [CA429] 1121
Failure Code [CA435] 1123
Failure Code [CA441] 1125
Failure Code [CA442] 1127
Failure Code [CA449] 1128
Failure Code [CA451] 1129
Failure Code [CA452] 1131
Failure Code [CA488] 1133
Failure Code [CA515] 1134
Failure Code [CA516] 1136
Failure Code [CA553] 1138
Failure Code [CA555] 1139
Failure Code [CA556] 1140
Failure Code [CA559] 1141
Failure Code [CA595] 1144
Failure Code [CA687] 1145
Failure Code [CA689] 1147
Failure Code [CA691] 1150
Failure Code [CA692] 1152
Failure Code [CA697] 1154
Failure Code [CA698] 1155
Failure Code [CA731] 1156
Failure Code [CA778] 1158
Failure Code [CA1117] 1163
Failure Code [CA1664] 1164
Failure Code [CA1669] 1166
Failure Code [CA1673] 1167
Failure Code [CA1677] 1168
Failure Code [CA1678] 1169
Failure Code [CA1682] 1170
Failure Code [CA1683] 1172
Failure Code [CA1684] 1174
Failure Code [CA1686] 1176
Failure Code [CA1691] 1177
Failure Code [CA1694] 1180
Failure Code [CA1695] 1183
Failure Code [CA1696] 1184
Failure Code [CA1712] 1186
Failure Code [CA1713] 1189
Failure Code [CA1714] 1191
Failure Code [CA1715] 1192
Failure Code [CA1776] 1193
Failure Code [CA1777] 1196
Failure Code [CA1843] 1199
Failure Code [CA1844] 1201
Failure Code [CA1879] 1204
Failure Code [CA1881] 1206
Failure Code [CA1883] 1208
Failure Code [CA1885] 1211
Failure Code [CA1887] 1213
Failure Code [CA1921] 1215
Failure Code [CA1922] 1218
Failure Code [CA1942] 1223
Failure Code [CA1993] 1224
Failure Code [CA2185] 1227
Failure Code [CA2186] 1228
Failure Code [CA2249] 1230
Failure Code [CA2271] 1231
Failure Code [CA2272] 1234
Failure Code [CA2288] 1237
Failure Code [CA2311] 1238
Failure Code [CA2349] 1239
Failure Code [CA2353] 1242
Failure Code [CA2357] 1244
Failure Code [CA2381] 1245
Failure Code [CA2382] 1248
Failure Code [CA2383] 1251
Failure Code [CA2386] 1254
Failure Code [CA2387] 1256
Troubleshooting Flowchart 1260
Failure Code [CA2555] 1261
Failure Code [CA2556] 1264
Failure Code [CA2637] 1267
Failure Code [CA2639] 1269
Failure Code [CA2771] 1272
Failure Code [CA2777] 1278
Failure Code [CA2976] 1281
Failure Code [CA3133] 1283
Failure Code [CA3134] 1286
Failure Code [CA3135] 1288
Failure Code [CA3142] 1291
Failure Code [CA3143] 1292
Failure Code [CA3144] 1293
Failure Code [CA3146] 1295
Failure Code [CA3147] 1296
Failure Code [CA3148] 1297
Failure Code [CA3151] 1299
Failure Code [CA3165] 1305
Failure Code [CA3229] 1307
Failure Code [CA3231] 1309
Failure Code [CA3232] 1311
Failure Code [CA3235] 1315
Failure Code [CA3239] 1317
Failure Code [CA3241] 1320
Failure Code [CA3242] 1323
Failure Code [CA3251] 1326
Failure Code [CA3253] 1328
Failure Code [CA3254] 1331
Failure Code [CA3255] 1334
Failure Code [CA3256] 1338
Failure Code [CA3311] 1340
Failure Code [CA3312] 1342
Failure Code [CA3313] 1345
Failure Code [CA3314] 1346
Failure Code [CA3315] 1347
Failure Code [CA3316] 1349
Failure Code [CA3317] 1350
Failure Code [CA3318] 1351
Failure Code [CA3319] 1353
Failure Code [CA3321] 1354
Failure Code [CA3322] 1356
Failure Code [CA3419] 1358
Failure Code [CA3421] 1360
Failure Code [CA3497] 1362
Failure Code [CA3498] 1363
Failure Code [CA3543] 1364
Failure Code [CA3545] 1371
Failure Code [CA3547] 1373
Failure Code [CA3558] 1374
Failure Code [CA3559] 1376
Failure Code [CA3562] 1378
Failure Code [CA3563] 1380
Failure Code [CA3567] 1383
Failure Code [CA3568] 1386
Failure Code [CA3571] 1390
Failure Code [CA3572] 1392
Failure Code [CA3574] 1394
Failure Code [CA3575] 1396
Failure Code [CA3577] 1398
Failure Code [CA3578] 1400
Failure Code [CA3582] 1402
Failure Code [CA3583] 1408
Failure Code [CA3596] 1410
Failure Code [CA3649] 1412
Failure Code [CA3681] 1414
Failure Code [CA3682] 1419
Failure Code [CA3713] 1425
Failure Code [CA3717] 1428
Failure Code [CA3718] 1429
Failure Code [CA3725] 1430
Failure Code [CA3741] 1433
Failure Code [CA3748] 1434
Failure Code [CA3751] 1436
Failure Code [CA3755] 1438
Failure Code [CA3866] 1440
Failure Code [CA3867] 1444
Failure Code [CA3868] 1447
Failure Code [CA3899] 1451
Failure Code [CA3911] 1453
Failure Code [CA3912] 1457
Failure Code [CA3932] 1459
Failure Code [CA3933] 1461
Failure Code [CA3934] 1463
Failure Code [CA3935] 1466
Failure Code [CA3936] 1468
Failure Code [CA4151] 1470
Failure Code [CA4152] 1474
Failure Code [CA4155] 1478
Failure Code [CA4156] 1480
Failure Code [CA4157] 1483
Failure Code [CA4158] 1485
Failure Code [CA4159] 1486
Failure Code [CA4161] 1487
Failure Code [CA4162] 1490
Failure Code [CA4163] 1493
Failure Code [CA4164] 1494
Failure Code [CA4165] 1496
Failure Code [CA4166] 1498
Failure Code [CA4168] 1499
Failure Code [CA4169] 1502
Failure Code [CA4171] 1504
Failure Code [CA4249] 1507
Failure Code [CA4251] 1509
Failure Code [CA4259] 1511
Failure Code [CA4261] 1514
Failure Code [CA4277] 1517
Failure Code [CA4281] 1520
Failure Code [CA4459] 1523
Failure Code [CA4461] 1525
Failure Code [CA4658] 1528
Failure Code [CA4731] 1532
Failure Code [CA4732] 1533
Failure Code [CA4739] 1534
Failure Code [CA4768] 1535
Failure Code [CA4769] 1537
Failure Code [CA4842] 1540
Failure Code [CA4952] 1544
Failure Code [CA5115] 1546
Failure Code [CA5179] 1549
Failure Code [CA5181] 1551
Failure Code [CA5383] 1553
Failure Code [D110KB] 1555
Failure Code [D19JKZ] 1557
Failure Code [D811MC] 1560
Failure Code [D862KA] 1561
Failure Code [D8ALKA] 1563
Failure Code [D8ALKB] 1566
Failure Code [D8AQKR] 1568
Failure Code [D8G1KT] 1575
Failure Code [D8G6KT] 1576
Failure Code [DA20MC] 1577
Failure Code [DA22KK] 1578
Failure Code [DA25KP] 1581
Failure Code [DA26KP] 1584
Failure Code [DA29KQ] 1587
Failure Code [DA2LKA] 1589
Failure Code [DA2LKB] 1592
Failure Code [DA2QKR] 1594
Failure Code [DA2RKR] 1603
Failure Code [DAF0MB] 1604
Failure Code [DAF0MC] 1605
Failure Code [DAF8KB] 1606
Failure Code [DAF9KQ] 1608
Failure Code [DAFGMC] 1609
Failure Code [DAFLKA] 1610
Failure Code [DAFLKB] 1613
Failure Code [DAFQKR] 1615
Failure Code [DAZ9KQ] 1623
Failure Code [DAZQKR] 1624
Failure Code [DB2QKR] 1631
Failure Code [DB2RKR] 1639
Failure Code [DBP0KM] 1644
Failure Code [DBP0KT] 1645
Failure Code [DBP5KB] 1646
Failure Code [DBP5KY] 1649
Failure Code [DBPQKR] 1652
Failure Code [DDNRKA] 1660
Failure Code [DDNRKY] 1662
Failure Code [DDNS00] 1664
Failure Code [DGH2KA] 1666
Failure Code [DGH2KB] 1668
Failure Code [DHA4KA] 1670
Failure Code [DHAAMA] 1672
Failure Code [DHACMA] 1674
Failure Code [DHPAMA] 1676
Failure Code [DHPBMA] 1679
Failure Code [DHS3MA] 1682
Failure Code [DHS4MA] 1685
Failure Code [DHS8MA] 1688
Failure Code [DHS9MA] 1691
Failure Code [DHSAMA] 1694
Failure Code [DHSBMA] 1697
Failure Code [DHSCMA] 1700
Failure Code [DHSDMA] 1703
Failure Code [DHSFMA] 1706
Failure Code [DHSGMA] 1709
Failure Code [DHSHMA] 1712
Failure Code [DHSJMA] 1715
Failure Code [DKR0MA] 1718
Failure Code [DKR1MA] 1721
Failure Code [DKULKA] 1724
Failure Code [DKULKB] 1726
Failure Code [DKULKY] 1728
Failure Code [DLM5KA] 1730
Failure Code [DLM5MB] 1732
Failure Code [DR10KA] 1734
Failure Code [DR12KA] 1737
Failure Code [DR20KA] 1739
Failure Code [DR21KX] 1741
Failure Code [DR30KA] 1743
Failure Code [DR31KX] 1745
Failure Code [DR40KA] 1747
Failure Code [DUMBKA] 1749
Failure Code [DUMBKB] 1752
Failure Code [DV20KB] 1754
Failure Code [DW43KA] 1756
Failure Code [DW43KB] 1758
Failure Code [DW43KY] 1760
Failure Code [DW45KA] 1762
Failure Code [DW45KB] 1765
Failure Code [DW45KY] 1768
Failure Code [DW4CKY] 1770
Failure Code [DW91KA] 1772
Failure Code [DW91KB] 1774
Failure Code [DW91KY] 1776
Failure Code [DWA2KA] 1778
Failure Code [DWA2KB] 1780
Failure Code [DWA2KY] 1782
Failure Code [DWK0KA] 1784
Failure Code [DWK0KB] 1786
Failure Code [DWK0KY] 1788
Failure Code [DWK2KA] 1790
Failure Code [DWK2KB] 1792
Failure Code [DWK2KY] 1794
Failure Code [DWK8KA] 1796
Failure Code [DWK8KB] 1798
Failure Code [DWK8KY] 1800
Failure Code [DWN5KA] 1802
Failure Code [DWN5KB] 1804
Failure Code [DWN5KY] 1806
Failure Code [DWPUKA] 1808
Failure Code [DWPUKB] 1810
Failure Code [DWPUKY] 1812
Failure Code [DXA8KA] 1814
Failure Code [DXA8KB] 1816
Failure Code [DXA9KA] 1818
Failure Code [DXA9KB] 1820
Failure Code [DXE0KA] 1822
Failure Code [DXE0KB] 1824
Failure Code [DXE4KA] 1826
Failure Code [DXE4KB] 1828
Failure Code [DXE4KY] 1830
Failure Code [DXE5KA] 1832
Failure Code [DXE5KB] 1834
Failure Code [DXE6KA] 1836
Failure Code [DXE6KB] 1838
Failure Code [DXE7KA] 1840
Failure Code [DXE7KB] 1842
Failure Code [DXE7KY] 1844
Failure Code [DXE8KA] 1846
Failure Code [DXE8KB] 1848
Failure Code [DXE8KY] 1850
Failure Code [DXE9KA] 1852
Failure Code [DXE9KB] 1854
Failure Code [DXE9KY] 1856
Failure Code [DXEAKA] 1858
Failure Code [DXEAKB] 1860
Failure Code [DXEAKY] 1862
Failure Code [DXEKKA] 1864
Failure Code [DXEKKB] 1866
Failure Code [DXEKKY] 1868
Failure Code [DXELKA] 1870
Failure Code [DXELKB] 1872
Failure Code [DXELKY] 1874
Failure Code [DY20KA] 1876
Failure Code [DY20MA] 1878
Failure Code [DY2CKB] 1880
Failure Code [DY2DKB] 1883
Failure Code [DY2EKB] 1885
Failure Code [F311KA] 1887
Failure Code [F311KB] 1889
Failure Code [F312KA] 1891
Failure Code [F312KB] 1893
Failure Code [F313KA] 1895
Failure Code [F313KB] 1897
Failure Code [F314KA] 1900
Failure Code [F314KB] 1902
Failure Code [F315KB] 1904
Failure Code [F315KY] 1906
Failure Code [F316KB] 1908
Failure Code [F316KY] 1910
Failure Code [F318KB] 1912
Failure Code [F318KY] 1915
Failure Code [F31AKB] 1917
Failure Code [F31AKY] 1919
Failure Code [F31BKB] 1921
Failure Code [F31BKY] 1923
Failure Code [F31CKB] 1925
Failure Code [F31CKY] 1927
Failure Code [F31DKB] 1929
Failure Code [F31DKY] 1931
Failure Code [F31EKB] 1933
Failure Code [F31EKY] 1935
Troubleshooting of Electrical System (E-Mode) 1937
E-1 Engine Does Not Start (Engine Does Not Crank) 1937
E-2 Manual Preheating System Does Not Operate 1943
E-3 Automatic Preheating System Does Not Operate 1946
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1948
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1950
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1953
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1954
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1955
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1956
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1957
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1958
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1959
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1960
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1961
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1962
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1963
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1964
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1966
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1967
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1968
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1969
E-23 Some Areas of Machine Monitor Screen are Not Shown 1970
E-24 Function Switch Does Not Operate 1971
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1972
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1973
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1974
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1975
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1976
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1977
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1978
E-32 Alarm Buzzer Cannot be Canceled 1980
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1981
E-34 Service Mode Cannot be Selected 1982
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1983
E-36 All Work Equipment, Swing and Travel Do Not Lock 1986
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1988
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1991
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1993
E-40 One-Touch Power Maximizing Function is Not Cancelled 1996
E-41 Alarm Does Not Sound During Travel 1997
E-42 Alarm Does Not Stop When Machine Stops 1999
E-43 Horn Does Not Sound 2000
E-44 Horn Does Not Stop 2003
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 2005
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2006
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 2008
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2009
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2010
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 2011
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 2012
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2013
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2014
E-54 “Swing” is Not Shown Correctly with Monitoring Function 2015
E-55 “Travel” is Not Shown Correctly with Monitoring Function 2016
E-56 Service is Not Shown Correctly with Monitoring Function 2017
E-57 Attachment Hydraulic Circuit Cannot be Changed 2019
E-58 KOMTRAX System Does Not Operate Correctly 2020
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2021
Information Shown in Troubleshooting Table (H-Mode) 2021
System Chart of Hydraulic and Mechanical Systems 2022
Failure Mode and Cause Table 2024
H-1 All Work Equipment, Swing and Travel Do Not Work 2033
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2034
H-3 Fine Control Performance or Response is Unsatisfactory 2037
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2038
H-5 Engine Speed Drops Largely or Engine Stops 2039
H-6 Speed or Power of Boom is Low 2041
H-7 Arm Speed or Power is Low 2045
H-8 Bucket Speed or Power is Low 2050
H-9 Work Equipment Does Not Move in Single Operation 2053
H-10 Hydraulic Drift of Boom is Large 2054
H-11 Hydraulic Drift of Arm is Large 2056
H-12 Hydraulic Drift of Bucket is Large 2058
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2059
H-14 Time Lag of Work Equipment is Large 2060
H-15 One-Touch Power Maximizing Function Does Not Operate 2061
H-16 Attachment Circuit Cannot be Changed 2062
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2063
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2064
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2065
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 2066
H-21 Machine Does Not Travel Straight 2067
H-22 Machine is Not Steered Correctly or Steering Power is Low 2069
H-23 Travel Speed is Low 2072
H-24 One of Tracks Does Not Run 2074
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2075
H-26 Upper Structure Does Not Swing to Right and Left 2076
H-27 Upper Structure Swings Only to Right or Left 2077
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 2078
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2079
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2080
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2081
H-32 Shock is Large When Upper Structure Stops Swing Operation 2082
H-33 There is Large Unusual Noise When It Stops Swing Operation 2083
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2084
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2085
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2086
H-37 Unusual Noise is Heard from Around Fan 2087
Troubleshooting of Engine (S-Mode) 2088
Information Shown in Troubleshooting Table (S-Mode) 2088
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2089
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2090
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2091
S-4 Engine Startability is Unsatisfactory 2093
S-5 Engine Does Not Pick Up Smoothly 2095
S-6 Engine Stops During Operation 2097
S-7 Engine Runs Rough or is Not Stable 2099
S-8 Engine Lacks Power 2100
S-9 KDPF Becomes Clogged in a Short Time 2102
S-10 Engine Oil Consumption is Excessive 2104
S-11 Oil Becomes Dirty Quickly 2105
S-12 Fuel Consumption is Excessive 2106
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2107
S-14 Oil Pressure Drops 2108
S-15 Fuel Mixes Into Engine Oil 2110
S-16 Water Mixes Into Engine Oil (Milky) 2111
S-17 Coolant Temperature Increases Too High (Overheating) 2112
S-18 Unusual Noise is Heard 2113
S-19 Vibration is Excessive 2114
S-20 Air Cannot be Bled from Fuel Circuit 2115
S-21 Active Regeneration is Done Frequently 2116
S-22 Active Regeneration Continues Long 2118
S-23 White Smoke is Exhausted During Active Regeneration 2119
S-24 DEF Consumption is Excessive 2120
S-25 There is Unusual Smell (Irritating Odor) 2122
S-26 Foreign Materials Enter DEF (DEF Increases) 2123
50 Disassembly and Assembly 2125
Table of Contents 2126
Precautions Before Work 2131
Related Information on Disassembly and Assembly 2132
How to Read This Manual 2132
Coating Materials List 2133
Special Tool List 2138
Sketches of Special Tools 2150
Engine and Cooling System 2156
Remove and Install Supply Pump Assembly 2156
Remove Supply Pump Assembly 2156
Install Supply Pump Assembly 2159
Remove and Install Injector Assembly 2162
How to Remove Injector Assembly 2162
How to Install Injector Assembly 2167
Remove and Install Cylinder Head Assembly 2175
How to Remove Cylinder Head Assembly 2176
How to Install Cylinder Head Assembly 2185
Remove and Install EGR Valve Assembly 2201
Remove EGR Valve Assembly 2201
Install EGR Valve Assembly 2202
Remove and Install EGR Cooler Assembly 2204
How to Remove EGR Cooler Assembly 2204
How to Install EGR Cooler Assembly 2208
Remove and Install Starter Assembly 2213
Remove Starting Motor Assembly 2213
Install Starting Motor Assembly 2214
Remove and Install Alternator Belt 2217
Remove Alternator Belt 2217
Install Alternator Belt 2219
Remove and Install Radiator Assembly 2222
How to Remove Radiator Assembly 2222
How to Install Radiator Assembly 2224
Remove and Install Hydraulic Oil Cooler Assembly 2227
How to Remove Hydraulic Oil Cooler Assembly 2227
How to Install Hydraulic Oil Cooler Assembly 2230
Remove and Install Aftercooler Assembly 2233
Remove Aftercooler Assembly 2233
Install Aftercooler Assembly 2235
Remove and Install Fan Clutch Assembly 2237
How to Remove Fan Clutch Assembly 2237
How to Install Fan Clutch Assembly 2242
Remove and Install Fan 2246
Remove Fan 2246
Install Fan 2246
Remove and Install Engine and Main Pump Assembly 2247
Remove Engine and Main Pump Assembly 2247
Install Engine and Main Pump Assembly 2256
Remove and Install Engine Front Oil Seal 2268
How to Remove Engine Front Oil Seal 2268
How to Install Engine Front Oil Seal 2271
Remove and Install Engine Rear Oil Seal 2275
How to Remove Engine Rear Oil Seal 2275
How to Install Engine Rear Oil Seal 2276
Remove and Install Fuel Cooler Assembly 2279
Remove Fuel Cooler Assembly 2279
Install Fuel Cooler Assembly 2279
Remove and Install Engine Hood Assembly 2281
How to Remove Engine Hood Assembly 2281
How to Install Engine Hood Assembly 2283
Remove and Install Fuel Tank Assembly 2288
Remove Fuel Tank Assembly 2288
Install Fuel Tank Assembly 2292
Remove and Install DEF Tank Assembly 2298
How to Remove DEF Tank Assembly 2298
How to Install DEF Tank Assembly 2303
Remove and Install DEF Tank Sensor Flange Assembly 2309
How to Remove DEF Tank Sensor Flange Assembly 2309
How to Install DEF Tank Sensor Flange Assembly 2315
Remove and Install DEF Tank Sensor 2321
Remove DEF Tank Sensor 2321
Install DEF Tank Sensor 2321
Remove and Install DEF Tank Strainer 2328
Remove DEF Tank Strainer 2328
Install DEF Tank Strainer 2328
Remove and Install DEF Tank Filler Port Filter 2329
Remove DEF Tank Filler Port Filter 2329
Install DEF Tank Filler Port Filter 2331
Remove and Install KDPF Assembly 2334
How to Remove KDPF Assembly 2334
How to Install KDPF Assembly 2336
Disassemble and Assemble KDPF Assembly 2338
Disassemble KDPF Assembly 2339
Assemble KDPF Assembly 2342
Remove and Install SCR Assembly 2347
How to Remove SCR Assembly 2347
How to Install SCR Assembly 2349
Remove and Install KDPF and SCR Assembly 2351
How to Remove KDPF and SCR Assembly 2351
Install KDPF and SCR Assembly 2358
Remove and Install KDPF and SCR Assembly Bracket 2364
Remove KDPF and SCR Assembly Bracket 2364
Install KDPF and SCR Assembly Bracket 2371
Remove and Install Bellows Pipe Assembly 2378
How to Remove Bellows Pipe Assembly 2378
How to Install Bellows Pipe Assembly 2380
Remove and Install KCCV Assembly 2384
Remove KCCV Assembly 2384
Install KCCV Assembly 2386
Remove and Install DEF Mixing Tube 2391
Remove DEF Mixing Tube 2391
Install DEF Mixing Tube 2397
Remove and Install DEF Injector 2403
Remove DEF Injector 2403
Install DEF Injector 2406
Remove and Install DEF Pump 2409
Remove DEF Pump 2409
Install DEF Pump 2412
Remove and Install DEF Hose 2415
Remove DEF Hose 2415
Install DEF Hose 2423
Remove and Install Air Cleaner Assembly 2429
Remove Air Cleaner Assembly 2429
Install Air Cleaner Assembly 2430
Remove and Install Air Conditioner Compressor Assembly 2432
Remove Air Conditioner Compressor Assembly 2432
How to Install Air Conditioner Compressor Assembly 2434
Remove and Install Air Conditioner Condenser Assembly 2437
How to Remove Air Conditioner Condenser Assembly 2437
How to Install Air Conditioner Condenser Assembly 2438
Power Train 2439
Remove and Install Travel Motor and Final Drive Assembly 2439
Remove Travel Motor and Final Drive Assembly 2439
Install Travel Motor and Final Drive Assembly 2440
Disassemble and Assemble Final Drive Assembly 2442
Disassemble Final Drive Assembly 2442
Assemble Final Drive Assembly 2446
Remove and Install Swing Motor and Swing Machinery Assembly 2455
Remove Swing Motor and Swing Machinery Assembly 2455
Install Swing Motor and Swing Machinery Assembly 2457
Disassemble and Assemble Swing Machinery Assembly 2461
Disassemble Swing Machinery Assembly 2461
Assemble Swing Machinery Assembly 2465
Remove and Install Swing Circle Assembly 2472
Remove Swing Circle Assembly 2472
Install Swing Circle Assembly 2472
Undercarriage and Frame 2474
Separate and Connect Track Assembly 2474
Separate Track Assembly 2474
Install Track Assembly 2476
Remove and Install Sprocket 2479
Remove Sprocket 2479
Install Sprocket 2479
Remove and Install Idler and Idler Cushion Assembly 2481
Remove Idler and Idler Cushion Assembly 2481
Install Idler and Idler Cushion Assembly 2482
Disassemble and Assemble Idler Assembly 2483
Disassemble Idler Assembly 2483
Assemble Idler Assembly 2484
Disassemble and Assemble Idler Cushion Assembly 2488
Disassemble Idler Cushion Assembly 2489
Assemble Idler Cushion Assembly 2489
Disassemble and Assemble Track Roller Assembly 2491
Disassemble Track Roller Assembly 2492
Assemble Track Roller Assembly 2493
Disassemble and Assemble Carrier Roller Assembly 2495
Disassemble Carrier Roller Assembly 2495
Assemble Carrier Roller Assembly 2497
Remove and Install Revolving Frame Assembly 2499
Remove Revolving Frame Assembly 2499
Install Revolving Frame Assembly 2501
Remove and Install Counterweight Assembly 2504
Remove Counterweight Assembly 2504
Install Counterweight Assembly 2507
Hydraulic System 2511
Remove and Install Center Swivel Joint Assembly 2511
Remove Center Swivel Joint Assembly 2511
Install Center Swivel Joint Assembly 2513
Disassemble and Assemble Center Swivel Joint Assembly 2516
Disassemble Center Swivel Joint Assembly 2516
Assemble Center Swivel Joint Assembly 2517
Remove and Install Hydraulic Tank Assembly 2519
Remove Hydraulic Tank Assembly 2519
How to Install Hydraulic Tank Assembly 2522
Remove and Install Main Pump Assembly 2526
Remove Main Pump Assembly 2526
Install Main Pump Assembly 2529
Remove and Install Control Valve Assembly 2533
How to Remove Control Valve Assembly 2533
How to Install Control Valve Assembly 2540
Disassemble and Assemble Control Valve Assembly 2548
Replace Pressure Compensation Valve Seal Ring 2548
Assemble Control Valve Assembly 2549
Disassemble and Assemble Work Equipment PPC Valve Assembly 2553
Disassemble Work Equipment PPC Valve Assembly 2553
How to Assemble Work Equipment PPC Valve Assembly 2553
Disassemble and Assemble Travel PPC Valve Assembly 2555
Disassemble Travel PPC Valve Assembly 2555
How to Assemble Travel PPC Valve Assembly 2556
Work Equipment 2558
Remove and Install Work Equipment Assembly 2558
Remove Work Equipment Assembly 2558
Install Work Equipment Assembly 2562
Remove and Install Boom Anti-drop Valve Assembly 2567
Remove Boom Anti-drop Valve Assembly 2567
Install Boom Anti-drop Valve Assembly 2569
Remove and Install Arm Anti-Drop Valve Assembly 2570
Remove Arm Anti-Drop Valve Assembly 2570
Install Arm Anti-Drop Valve Assembly 2572
Disassemble and Assemble Anti-Drop Valve Assembly 2573
Disassemble Anti-Drop Valve Assembly 2573
Assemble Anti-Drop Valve Assembly 2573
Disassemble and Assemble Work Equipment Cylinder Assembly 2574
How to Disassemble Work Equipment Cylinder Assembly 2574
How to Assemble Work Equipment Cylinder Assembly 2577
CAB Related Parts 2583
Remove and Install Operator Cab Assembly 2583
How to Remove Operator Cab Assembly 2583
Install Operator CAB Assembly 2591
Remove and Install Operator Cab Glass (Adhered Glass) 2598
Remove Operator CAB Glass (Adhered Glass) 2600
Install Operator CAB Glass (Adhered Glass) 2600
Remove and Install Front Window Assembly 2610
Remove Front Window Assembly 2610
Install Front Window Assembly 2613
Remove and Install Floor Frame Assembly 2619
How to Remove Floor Frame Assembly 2619
How to Install Floor Frame Assembly 2626
Remove and Install Air Conditioner Unit Assembly 2633
Remove Air Conditioner Unit Assembly 2633
Install Air Conditioner Unit Assembly 2639
Remove and Install Operator Seat 2646
Remove Operator’s Seat 2646
Install Operator’s Seat 2648
How to Remove and Install Seat Belt 2651
How to Remove Seat Belt 2651
How to Install Seatbelt 2652
Remove and Install Work Equipment Control Lever Assembly 2653
How to Remove Work Equipment Control Lever Assembly 2653
How to Install Work Equipment Control Lever Assembly 2659
Remove and Install Front Wiper Assembly 2668
Remove Front Wiper Assembly 2668
Install Front Wiper Assembly 2673
Electrical System 2682
Remove and Install Engine Controller Assembly 2682
Remove Engine Controller Assembly 2682
Install Engine Controller Assembly 2683
Remove and Install Pump Controller Assembly 2685
Remove Pump Controller Assembly 2685
Install Pump Controller Assembly 2689
Remove and Install KomVision Controller Assembly 2694
Remove KomVision Controller Assembly 2694
Install KomVision Controller Assembly 2695
Remove and Install Machine Monitor Assembly 2696
Remove Machine Monitor Assembly 2696
Install Machine Monitor Assembly 2699
Remove and Install Pump Swash Plate Sensor 2703
Remove Pump Swash Plate Sensor 2703
Install Pump Swash Plate Sensor 2704
Remove and Install Mass Air Flow and Temperature Sensor 2705
How to Remove Mass Air Flow and Temperature Sensor 2705
How to Install Mass Air Flow and Temperature Sensor 2705
Remove and Install KCCV Crankcase Pressure Sensor 2707
How to Remove KCCV Crankcase Pressure Sensor 2707
How to Install KCCV Crankcase Pressure Sensor 2708
Remove and Install SCR Temperature Sensor 2709
Remove SCR Temperature Sensor 2709
Install SCR Temperature Sensor 2711
Remove and Install KomVision Camera 2714
Remove KomVision Camera 2714
Install KomVision Camera 2715
Remove and Install Gateway Function Controller Assembly 2717
Remove Gateway Function Controller Assembly 2717
How to Install Gateway Function Controller Assembly 2722
Remove and Install Communication Terminal Wiring Harness 2727
Remove Communication Terminal Wiring Harness 2727
Install Communication Terminal Wiring Harness 2735
Remove and Install Communication Terminal 2744
Remove Communication Terminal 2744
Install Communication Terminal 2746
60 Maintenance Standard 2749
Table of Contents 2750
Engine and Cooling System 2751
Maintenance Standard for Engine Mount 2751
Maintenance Standard for Cooling System 2752
Power Train 2754
Maintenance Standard for Swing Circle 2754
Maintenance Standard for Swing Machinery 2755
Maintenance Standard for Final Drive 2757
Maintenance Standard for Sprocket 2759
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2760
Undercarriage and Frame 2761
Maintenance Standard for Track Frame and Idler Cushion 2761
Maintenance Standard for Idler 2763
Maintenance Standard for Track Roller 2765
Maintenance Standard for Carrier Roller 2766
Maintenance Standard for Track Shoes 2767
Maintenance Standard for Triple Shoes 2770
Maintenance Standard for Swamp Shoes 2771
Maintenance Standard for Road Liner 2772
Hydraulic System 2773
Maintenance Standard for Hydraulic Tank 2773
Maintenance Standard for Main Pump 2774
Maintenance Standard for LS-EPC Valve 2775
Maintenance Standard for PC-EPC Valve 2776
Maintenance Standard for Swing Motor 2777
Maintenance Standard for Travel Motor 2780
Maintenance Standard for Control Valve 2783
Maintenance Standard for Boom Anti-Drop Valve 2793
Maintenance Standard for Arm Anti-Drop Valve 2795
Maintenance Standard for Work Equipment and Swing PPC Valve 2797
Maintenance Standard for Travel PPC Valve 2800
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2803
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2804
Maintenance Standard for 2nd-Line Attachment PPC Valve 2806
Maintenance Standard for Solenoid Valve 2808
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2809
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2810
Maintenance Standard for Center Swivel Joint 2811
Work Equipment 2812
Maintenance Standard for Work Equipment Linkage 2812
Dimensions of Arm 2817
Dimensions of Bucket 2819
Maintenance Standard for Boom Cylinder (Large Diameter Piston) 2821
Maintenance Standard for Arm Cylinder 2822
Maintenance Standard for Bucket Cylinder 2823
80 Appendix 2825
Table of Contents 2826
Precautions Before Work 2828
Air Conditioner System 2829
Precautions for Refrigerant 2829
Air Conditioner Component 2830
Specifications of Air Conditioner 2832
Structure and Function of Refrigeration Cycle 2833
Outline of Refrigeration Cycle 2834
Component Parts of Air Conditioner System 2836
Air Conditioner Unit 2836
Configuration Diagram of Air Conditioner Unit 2836
Function of Air Conditioner Unit 2838
Component Parts of Air Conditioner Unit 2840
Function of Evaporator as Air Conditioner Unit Component 2841
Function of Heater Core as Air Conditioner Unit Component 2841
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2841
Function of Servo Motor as Air Conditioner Unit Component 2841
Structure of Expansion Valve as Air Conditioner Unit Component 2842
Function of Expansion Valve as Air Conditioner Unit Component 2842
Operate Expansion Valve as Air Conditioner Unit Component 2842
Function of Dual Pressure Switch 2843
Air Conditioner Controller 2844
Structure of Air Conditioner Controller 2844
Compressor 2845
Structure of Compressor 2845
Specifications of Compressor 2845
Function of Compressor 2845
Condenser 2846
Structure of Condenser 2846
Specifications of Condenser 2846
Function of Condenser 2846
Air Conditioner Related Sensors 2848
Structure of Sunlight Sensor 2848
Function of Sunlight Sensor 2848
Structure of Outside Temperature Sensor 2848
Function of Outside Air Temperature Sensor 2848
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2850
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2852
System Diagram of Air Conditioner 2854
Input and Output Signals of Air Conditioner Controller 2855
Function of Air Conditioner Controller 2856
Locations of Air Conditioner Parts and Layout of Connectors 2857
Examine Air Leakage (Duct) 2861
How to Examine Air Leakage (Duct) 2861
Examine Air Conditioner with Self-Diagnosis Function 2863
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2864
Examine Vent (Mode) Changeover 2865
How to Examine Vent (Mode) Changeover 2865
Examine Fresh/Recirc Air Changeover 2867
How to Examine Fresh/Recirc Air Changeover 2867
Examine Sunlight Sensor 2868
How to Examine Sunlight Sensor 2868
Examine Refrigerant (Dual) Pressure Switch 2869
How to Examine Refrigerant (Dual) Pressure Switch 2869
Examine Relay 2870
How to Examine Relay 2870
Air Conditioner Troubleshooting Chart 1 2871
Air Conditioner Troubleshooting Chart 2 2872
Information Shown in Troubleshooting Table 2875
Failure Code [879AKA] 2876
Failure Code [879AKB] 2877
Failure Code [879BKA] 2878
Failure Code [879BKB] 2880
Failure Code [879CKA] 2882
Failure Code [879CKB] 2883
Failure Code [879DKZ] 2884
Failure Code [879EMC] 2886
Failure Code [879FMC] 2887
Failure Code [879GKX] 2888
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2890
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2892
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2895
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2897
Troubleshooting by Gauge Pressure 2899
Connect Service Tool 2902
How to Connect Service Tool 2902
Precautions for Disconnection and Connection of Air Conditioner Piping 2904
Handle Compressor Oil 2906
Replace Desiccant 2908
90 Circuit Diagrams 2911
Table of Contents 2912
Hydraulic Circuit Diagram 2913
Symbols Used in Hydraulic Circuit Diagram 2913
Hydraulic Circuit Diagram 2917
Electrical Circuit Diagram 2919
Symbols Used in Electric Circuit Diagram 2919
Electrical Circuit Diagram (1/9) 2923
Electrical Circuit Diagram (2/9) 2925
Electrical Circuit Diagram (3/9) 2927
Electrical Circuit Diagram (4/9) 2929
Electrical Circuit Diagram (5/9) 2931
Electrical Circuit Diagram (6/9) 2933
Electrical Circuit Diagram (7/9) 2935
Electrical Circuit Diagram (8/9) 2937
Electrical Circuit Diagram (9/9) 2939
Index 2941Cover 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 When You Discard Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions When You Add 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
Disconnect and Connect Connector with Lock to Pull 66
Disconnect and Connect Connector with Lock to Push 67
Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
01 Specification 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: PC210LC-11 91
Working Range Drawings 93
Working Range: PC210LC-11 93
Specifications 94
Specifications: PC210LC-11 94
Weight Table 97
Weight Table: PC210LC-11 97
Table of Fuel, Coolant, and Lubricants 99
Fuel, Coolant, Lubricant 100
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 100
10 Structure and Function 103
Table of Contents 104
Urea SCR System 108
Layout Drawing of Urea SCR System 109
Urea SCR System Diagram 114
Function of Urea SCR System 115
Function of DEF System 115
Inducement Strategy 117
Component Parts of Urea SCR System 131
DEF Mixing Tube 131
SCR Assembly 132
DEF Tank 134
DEF Pump 136
DEF Injector 137
DEF Hose 138
DEF Tank Heating Valve 139
Boot-up System 140
Layout Drawing of Boot-up System 140
System Operating Lamp System 142
System Diagram of System Operating Lamp System 142
Function of Operation Lamp System 142
Operation of System Operating Lamp System 142
Battery Disconnect Switch 143
Function of Battery Disconnect Switch 143
Engine System 144
Layout Drawing of Engine System 144
Specifications of Engine System 145
Function of Engine System 145
Engine Control System 146
System Diagram of Engine Control 146
Operation of Engine Control System 147
Auto-Deceleration System 149
System Diagram of Auto-Deceleration System 149
Function of Auto-Deceleration System 149
Operation of Auto-Deceleration System 150
Engine Automatic Warm-up System 151
System Diagram of Engine Automatic Warm-up System 151
Function of Engine Automatic Warm-up System 152
Overheat Prevention System 153
Overheat Prevention System Diagram 153
Function of Overheat Prevention System 154
Turbocharger Protection System 156
System Diagram of Turbocharger Protection System 156
Function of Turbocharger Protection System 157
Automatic Idle Stop System 158
System Diagram of Automatic Idle Stop System 158
Function of Automatic Idle Stop System 158
Operation of Automatic Idle Stop System 158
Component Parts of Engine System 161
VGT 161
EGR System 166
EGR Valve 168
EGR Cooler 170
KCCV System 172
KCCV Ventilator 174
KDPF 176
Cooling System 180
Layout Drawing of Cooling System 180
Specifications of Cooling System 181
Fan Speed Control System of Fan Clutch 182
Fan Speed Control System Diagram of Fan Clutch 182
Function of Fan Speed Control System of Fan Clutch 183
Engine Output Control System of Fan Clutch 184
Engine Output Control System Diagram of Fan Clutch 184
Function of Engine Output Control System of Fan Clutch 184
Component Parts of Cooling System 186
Fan Clutch 186
Control System 187
Layout Drawing of Control System 187
Machine Monitor System 190
System Diagram of Machine Monitor System 190
Function of Machine Monitor System 191
KomVision System 192
Layout Drawing of KomVision System 192
System Diagram of KomVision System 194
Function of KomVision System 194
KOMTRAX System 196
System Diagram of KOMTRAX System 196
Function of KOMTRAX System 196
Component Parts of Control System 197
Machine Monitor 197
KomVision Controller 212
KomVision Camera 216
Gateway Function Controller 217
Communication Terminal 220
Pump Controller 222
Resistor for PC-EPC Valve 226
CAN Terminating Resistor 227
Engine Controller 228
Fuel Control Dial 235
Hydraulic System 237
Layout Drawing of Hydraulic System 237
CLSS 243
Structure of CLSS 243
Operation of Unload Valve and LS Pressure 245
Pump Swash Plate Angle (Oil Flow) Control 246
Pressure Compensation Control 262
Engine and Pump Combined Control System 265
Engine and Pump Combined Control System Diagram 265
Function of Engine and Pump Combined Control System 266
Pump and Valve Control System 271
Pump and Valve Control System Diagram 271
Function of Pump and Valve Control System 272
Component Parts of Hydraulic System 274
Hydraulic Tank 274
Main Pump 276
Control Valve 302
Work Equipment System 361
Layout Drawing of Work Equipment System 361
Structure of Valve Control 366
One-Touch Power Maximizing System 368
System Diagram of One-Touch Power Maximizing System 368
Function of One-Touch Power Maximizing System 369
PPC Lock System 370
System Diagram of PPC Lock 370
Function of PPC Lock System 370
Work Equipment and Travel Automatic Lock System 371
System Diagram of Lock Lever Automatic Lock System 371
Function of Work Equipment and Travel Automatic Lock System 371
Operation of Lock Lever Automatic Lock System 372
Attachment Oil Flow Adjuster System 373
Attachment Oil Flow Adjuster System Diagram 373
Function of Attachment Oil Flow Adjuster System 374
Tool Control System 375
Tool Control System Diagram 375
Component Parts of Work Equipment System 377
Work Equipment and Swing PPC Valve 377
1st-Line Attachment PPC Valve (with EPC Valve) 384
2nd-Line Attachment PPC Valve 392
Solenoid Valve 394
Boom Anti-drop Valve 397
Arm Anti-Drop Valve 401
Attachment Circuit Selector Valve (For High Pressure) 406
Attachment Circuit Selector Valve (For Low Pressure) 408
1st-Line Attachment Variable Relief Valve 409
2nd-Line Attachment Variable Relief Valve 412
Attachment Bypass Solenoid Valve 415
Pilot Circuit Accumulator 417
Attachment Circuit Accumulator 418
Swing System 419
Layout Drawing of Swing System 419
Swing Control System Diagram 423
Function of Swing Control System 423
Component Parts of Swing System 427
Swing Motor 427
Swing Machinery 439
Swing Circle 441
Travel System 442
Layout Drawing of Travel System 442
System Diagram of Travel Control System 446
Function of Travel Control System 447
Component Parts of Travel System 448
Travel Motor 448
Final Drive 460
Travel PPC Valve 463
Center Swivel Joint 467
Undercarriage and Frame 469
Layout Drawing of Undercarriage 469
Specifications of Undercarriage 470
Work Equipment 471
Structure of Work Equipment 471
Function of Work Equipment 471
Work Equipment Clearance Adjustment Shim 472
Function of Work Equipment Clearance Adjustment Shim 472
Bucket Clearance Adjustment Shim 472
Function of Bucket Clearance Adjustment Shim 472
CAB Related Parts 473
ROPS CAB 473
Structure of ROPS CAB 473
Function of ROPS CAB 473
CAB Mount 474
Structure of CAB Mount 474
Function of CAB Mount 474
CAB Tipping Stopper 475
Structure of CAB Tipping Stopper 475
Function of CAB Tipping Stopper 475
20 Standard Value Table 477
Table of Contents 478
Standard Value Table for Engine 479
Standard Value Table for Engine: PC210LC-11 479
Standard Value Table for Machine 483
Standard Value Table for Machine: PC210LC-11 483
Machine Posture and Procedures to Measure Performance 496
Standard Value Table for Electricity 500
Standard Value Table for Electricity 500
30 Testing and Adjusting 511
Table of Contents 512
Precautions Before Work 515
Related Information on Testing and Adjusting 516
Tools for Testing and Adjusting 516
Sketch of Tools for Testing and Adjusting 523
Engine and Cooling System 525
Examine Engine Speed 525
How to Examine Engine Speed 525
Examine Boost Pressure 528
How to Examine Boost Pressure on Machine Monitor 528
How to Examine Boost Pressure by Testing Tool 529
Examine Exhaust Gas Color 530
How to Examine Exhaust Gas Color with the Handy Smoke Checker 530
How to Examine Exhaust Gas Color with Smoke Meter 531
Examine Mass Air Flow and Temperature Sensor 533
How to Examine Mass Air Flow and Temperature Sensor 533
Examine and Adjust Valve Clearance 535
Check Valve Clearance 535
Adjust Valve Clearance 536
Examine Compression Pressure 538
How to Examine Compression Pressure 538
Examine Blowby Pressure 543
How to Examine Blowby Pressure 543
Examine Engine Oil Pressure 545
How to Examine Engine Oil Pressure 545
Examine EGR Valve and VGT Oil Pressure 546
How to Examine EGR Valve and VGT Oil Pressure 546
Examine Fuel Pressure 548
How to Examine Fuel Pressure 549
Examine Fuel Discharge, Return and Leakage 554
How to Examine Fuel Discharge, Return, and Leakage 555
Bleed Air from Fuel System 561
How to Bleed Air from Fuel System 561
Examine Fuel Circuit for Leakage 562
How to Examine Fuel System for Leakage 562
Handle Cylinder Cut-out Mode Operation 564
Handle No-Injection Cranking Operation 565
Examine and Adjust Air Conditioner Compressor Belt Tension 566
How to Examine Air Conditioner Compressor Belt 566
How to Adjust Air Conditioner Compressor Belt 566
Examine Fan Belt and Alternator Belt 568
How to Examine Fan Belt and Alternator Belt 568
Examine Automatic Tensioner 569
How to Examine Automatic Tensioner 569
Examine Cooling Fan Speed 570
How to Examine Cooling Fan Speed 570
Write Correction for Ash in Soot Accumulation to Engine Controller 571
How to Write Correction for Ash in Soot Accumulation to Engine Controller 571
Examine SCR Related Functions 572
Examine DEF Pump Raised Pressure 576
Examine Injection Volume from DEF Injector 579
Examine DEF Line Heater Relay 1 584
Examine DEF Line Heater Relay 2 587
Examine DEF Pump Heater Relay 590
Examine DEF Tank Heater Valve 593
Examine SCR Denitration Efficiency 596
Clean DEF Tank 600
How to Clean DEF Tank 600
Clean DEF Pump 604
How to Clean DEF Pump 604
Bleed Air from Coolant Circuit of DEF Tank 611
How to Bleed Air from Coolant Circuit of DEF Tank 611
Power Train 613
Examine Swing Circle Bearing Clearance 613
How to Examine Swing Circle Bearing Clearance 613
Undercarriage and Frame 614
Examine and Adjust Track Tension 614
How to Examine Track Tension 614
How to Adjust Track Tension 614
Hydraulic System 616
Release Remained Pressure in Hydraulic Circuit 616
How to Release Remained Pressure in Hydraulic System 616
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 617
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 618
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 624
Examine Oil Pressure of Control Circuit 627
Examine Oil Pressure in Control Circuit 627
Examine and adjust oil pressure in pump PC control circuit 629
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 629
Examine PC-EPC Valve Outlet Pressure 630
How to Adjust Oil Pressure in Pump PC Control Circuit 631
Examine and Adjust Oil Pressure in Pump LS Control Circuit 633
Examine LS Differential Pressure with Machine Monitor 633
Examine LS Differential Pressure by Testing Tool 634
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 637
How to Examine LS-EPC Valve Outlet Pressure 638
Adjust LS Valve 639
Examine Outlet Pressure of Solenoid Valve 640
How to Examine Outlet Pressure of Solenoid Valve 640
Operating Condition of Solenoid Valve 641
Examine PPC Valve Outlet Pressure 644
Examine Outlet Pressure in PPC Valve 644
Examine Attachment Circuit Oil Pressure 646
How to Examine Attachment Circuit Oil Pressure 646
Adjust Play of Work Equipment and Swing PPC Valves 647
How to Adjust Play of Work Equipment and Swing PPC Valves 647
Examine Pump Swash Plate Sensor 648
How to Examine pump swash plate sensor 648
Examine Parts Which Cause Hydraulic Drift of Work Equipment 649
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 649
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 649
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 650
Examine Oil Leakage 651
How to Examine Oil Leakage from Boom Cylinder 651
How to Examine Oil Leakage from Arm Cylinder 651
How to Examine Oil Leakage from Bucket Cylinder 652
How to Examine Oil Leakage from Swing Motor 653
How to Examine Oil Leakage from Travel Motor 653
Bleed Air from Hydraulic System 654
How to Bleed Air from Hydraulic System 656
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 658
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 658
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 662
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 662
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 666
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 666
CAB Related Parts 673
Examine CAB Tipping Stopper 673
How to Examine Cab Tipping Stopper 673
How to Adjust Mirrors 674
Procedure to Adjust Machine Left Front Mirror (A) 674
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 675
Procedure to Adjust Machine Right Front Mirror (B) 676
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 677
Procedure to Adjust Machine Right Side Mirror (C) 678
Electrical System 680
Set and Operate Machine Monitor 680
Operator Mode 684
Function to Show Technician Identification Status Screen 684
Function to Show Operator Identification Input Screen 684
Examine Function by LCD (Liquid Crystal Display) 685
Examine Function of Service Meter 685
Usage Limitation and Maintenance Password Change Function 685
Service Mode 688
How to See Pre-defined Monitoring Information 690
How to Examine Self-Define Monitor Information 697
Abnormality Record Menu 708
How to See Maintenance Record 712
Maintenance Mode Setting 713
Set Phone Number Entry 717
Default Menu 719
Diagnostic Tests Menu 731
Adjustment Menu 740
No-Injection Cranking Operation 767
KOMTRAX Settings Menu 769
Show Service Message 771
Start Up KOMTRAX System 773
Adjust Rearview Camera Angle 778
How to Adjust Rearview Camera Angle 778
Adjust KomVision Camera Angle 781
Adjust KomVision Related Function 783
Setting of KomVision (Main Setting) 783
Setting of KomVision (Camera Setting) 785
Setting of KomVision (Camera Calibration) 787
KomVision screen – Check 12 m visibility 800
Set Region of Bluetooth(R) Compatible Radio 803
Set Region of Bluetooth(R) Compatible Radio 803
Handle Voltage Circuit of Engine Controller 805
Handle Battery Disconnect Switch 806
Examine Diodes 807
Examine Diodes by Digital Tester 807
How to Examine Diodes by Analog Tester 807
Pm Clinic 808
Pm Clinic Service 808
Pm Clinic Check Sheet 810
40 Troubleshooting 823
Table of Contents 824
Precautions Before Work 835
Related Information to Troubleshooting 836
General Troubleshooting Points 836
Troubleshooting Points for Urea SCR System 837
Sequence of Events in Troubleshooting 851
Checks Before Troubleshooting 853
Inspection Procedure Before Troubleshooting 855
Walk-Around Check 855
Test in Accordance with Testing Procedure 857
Examine Fuel Level and Type 857
Examine for Impure Ingredient in Fuel 857
Examine Fuel Prefilter 858
Examine Water Separator, Drain Water and Sediment 858
How to Replace Fuel Prefilter Cartridge 859
Examine Fuel Main Filter 860
Examine Engine Oil Level (Oil Quantity in Oil Pan) 862
Examine Coolant Level (Reservoir Tank) 863
Examine Air Cleaner Clogging 863
Clean Outer Element 864
Replace Element 866
Examine Hydraulic Oil Level 867
Examine Hydraulic Oil Strainer 868
Examine Hydraulic Oil Filter 869
Examine Oil Level in Swing Machinery Case 870
Examine Oil Level in Damper Case 871
Examine Oil Level in Final Drive Case 871
Bleed Air from Fuel System 872
Bleed Air from Hydraulic System 872
How to Examine Electric Equipment 872
Preparation for Troubleshooting of Electrical System 880
Procedure for Troubleshooting 893
Symptom and Troubleshooting Numbers 896
Information Shown in Troubleshooting Table 900
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 902
Connector List and Layout (Halogen lamp Specifications) 905
Connector List and Layout (LED lamp Specifications) 918
Connector Contact Connection Table 932
T-Branch Box and T-Branch Adapter Table 972
Fuse Location Table 978
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 981
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 985
Failure Code Table 987
Troubleshooting by Failure Code (Display of Code) 1006
Failure Code [6AZ0ZG] 1006
Failure Code [879AKA] 1008
Failure Code [879AKB] 1009
Failure Code [879BKA] 1010
Failure Code [879BKB] 1012
Failure Code [879CKA] 1014
Failure Code [879CKB] 1015
Failure Code [879DKZ] 1016
Failure Code [879EMC] 1018
Failure Code [879FMC] 1019
Failure Code [879GKX] 1020
Failure Code [989L00] 1022
Failure Code [989M00] 1023
Failure Code [989N00] 1024
Failure Code [A1U0N3] 1025
Failure Code [A1U0N4] 1027
Failure Code [A900FR] 1029
Failure Code [A900N6] 1030
Failure Code [A900NY] 1031
Failure Code [AA10NX] 1032
Failure Code [AB00KE] 1034
Failure Code [AQ10N3] 1037
Failure Code [AS00N3] 1039
Failure Code [AS00R2] 1041
Failure Code [AS00R3] 1042
Failure Code [AS00R4] 1043
Failure Code [AS00R5] 1044
Failure Code [AS00R6] 1045
Failure Code [AS00ZK] 1046
Failure Code [AS10KM] 1047
Failure Code [AS10NR] 1048
Failure Code [AS10NT] 1049
Failure Code [B@BAZG] 1050
Failure Code [B@BAZK] 1051
Failure Code [B@BCNS] 1053
Failure Code [B@BCQA] 1054
Failure Code [B@BCZK] 1056
Failure Code [B@HANS] 1058
Failure Code [CA115] 1059
Failure Code [CA122] 1060
Failure Code [CA123] 1062
Failure Code [CA131] 1064
Failure Code [CA132] 1066
Failure Code [CA144] 1068
Failure Code [CA145] 1070
Failure Code [CA153] 1072
Failure Code [CA154] 1075
Failure Code [CA187] 1077
Failure Code [CA221] 1079
Failure Code [CA222] 1081
Failure Code [CA227] 1083
Failure Code [CA234] 1084
Failure Code [CA238] 1085
Failure Code [CA239] 1087
Failure Code [CA249] 1089
Failure Code [CA256] 1091
Failure Code [CA271] 1093
Failure Code [CA272] 1095
Failure Code [CA322] 1097
Failure Code [CA323] 1099
Failure Code [CA324] 1101
Failure Code [CA325] 1103
Failure Code [CA331] 1105
Failure Code [CA332] 1107
Failure Code [CA343] 1109
Failure Code [CA351] 1110
Failure Code [CA352] 1111
Failure Code [CA356] 1114
Failure Code [CA357] 1116
Failure Code [CA386] 1118
Failure Code [CA428] 1119
Failure Code [CA429] 1121
Failure Code [CA435] 1123
Failure Code [CA441] 1125
Failure Code [CA442] 1127
Failure Code [CA449] 1128
Failure Code [CA451] 1129
Failure Code [CA452] 1131
Failure Code [CA488] 1133
Failure Code [CA515] 1134
Failure Code [CA516] 1136
Failure Code [CA553] 1138
Failure Code [CA555] 1139
Failure Code [CA556] 1140
Failure Code [CA559] 1141
Failure Code [CA595] 1144
Failure Code [CA687] 1145
Failure Code [CA689] 1147
Failure Code [CA691] 1150
Failure Code [CA692] 1152
Failure Code [CA697] 1154
Failure Code [CA698] 1155
Failure Code [CA731] 1156
Failure Code [CA778] 1158
Failure Code [CA1117] 1163
Failure Code [CA1664] 1164
Failure Code [CA1669] 1166
Failure Code [CA1673] 1167
Failure Code [CA1677] 1168
Failure Code [CA1678] 1169
Failure Code [CA1682] 1170
Failure Code [CA1683] 1172
Failure Code [CA1684] 1174
Failure Code [CA1686] 1176
Failure Code [CA1691] 1177
Failure Code [CA1694] 1180
Failure Code [CA1695] 1183
Failure Code [CA1696] 1184
Failure Code [CA1712] 1186
Failure Code [CA1713] 1189
Failure Code [CA1714] 1191
Failure Code [CA1715] 1192
Failure Code [CA1776] 1193
Failure Code [CA1777] 1196
Failure Code [CA1843] 1199
Failure Code [CA1844] 1201
Failure Code [CA1879] 1204
Failure Code [CA1881] 1206
Failure Code [CA1883] 1208
Failure Code [CA1885] 1211
Failure Code [CA1887] 1213
Failure Code [CA1921] 1215
Failure Code [CA1922] 1218
Failure Code [CA1942] 1223
Failure Code [CA1993] 1224
Failure Code [CA2185] 1227
Failure Code [CA2186] 1228
Failure Code [CA2249] 1230
Failure Code [CA2271] 1231
Failure Code [CA2272] 1234
Failure Code [CA2288] 1237
Failure Code [CA2311] 1238
Failure Code [CA2349] 1239
Failure Code [CA2353] 1242
Failure Code [CA2357] 1244
Failure Code [CA2381] 1245
Failure Code [CA2382] 1248
Failure Code [CA2383] 1251
Failure Code [CA2386] 1254
Failure Code [CA2387] 1256
Troubleshooting Flowchart 1260
Failure Code [CA2555] 1261
Failure Code [CA2556] 1264
Failure Code [CA2637] 1267
Failure Code [CA2639] 1269
Failure Code [CA2771] 1272
Failure Code [CA2777] 1278
Failure Code [CA2976] 1281
Failure Code [CA3133] 1283
Failure Code [CA3134] 1286
Failure Code [CA3135] 1288
Failure Code [CA3142] 1291
Failure Code [CA3143] 1292
Failure Code [CA3144] 1293
Failure Code [CA3146] 1295
Failure Code [CA3147] 1296
Failure Code [CA3148] 1297
Failure Code [CA3151] 1299
Failure Code [CA3165] 1305
Failure Code [CA3229] 1307
Failure Code [CA3231] 1309
Failure Code [CA3232] 1311
Failure Code [CA3235] 1315
Failure Code [CA3239] 1317
Failure Code [CA3241] 1320
Failure Code [CA3242] 1323
Failure Code [CA3251] 1326
Failure Code [CA3253] 1328
Failure Code [CA3254] 1331
Failure Code [CA3255] 1334
Failure Code [CA3256] 1338
Failure Code [CA3311] 1340
Failure Code [CA3312] 1342
Failure Code [CA3313] 1345
Failure Code [CA3314] 1346
Failure Code [CA3315] 1347
Failure Code [CA3316] 1349
Failure Code [CA3317] 1350
Failure Code [CA3318] 1351
Failure Code [CA3319] 1353
Failure Code [CA3321] 1354
Failure Code [CA3322] 1356
Failure Code [CA3419] 1358
Failure Code [CA3421] 1360
Failure Code [CA3497] 1362
Failure Code [CA3498] 1363
Failure Code [CA3543] 1364
Failure Code [CA3545] 1371
Failure Code [CA3547] 1373
Failure Code [CA3558] 1374
Failure Code [CA3559] 1376
Failure Code [CA3562] 1378
Failure Code [CA3563] 1380
Failure Code [CA3567] 1383
Failure Code [CA3568] 1386
Failure Code [CA3571] 1390
Failure Code [CA3572] 1392
Failure Code [CA3574] 1394
Failure Code [CA3575] 1396
Failure Code [CA3577] 1398
Failure Code [CA3578] 1400
Failure Code [CA3582] 1402
Failure Code [CA3583] 1408
Failure Code [CA3596] 1410
Failure Code [CA3649] 1412
Failure Code [CA3681] 1414
Failure Code [CA3682] 1419
Failure Code [CA3713] 1425
Failure Code [CA3717] 1428
Failure Code [CA3718] 1429
Failure Code [CA3725] 1430
Failure Code [CA3741] 1433
Failure Code [CA3748] 1434
Failure Code [CA3751] 1436
Failure Code [CA3755] 1438
Failure Code [CA3866] 1440
Failure Code [CA3867] 1444
Failure Code [CA3868] 1447
Failure Code [CA3899] 1451
Failure Code [CA3911] 1453
Failure Code [CA3912] 1457
Failure Code [CA3932] 1459
Failure Code [CA3933] 1461
Failure Code [CA3934] 1463
Failure Code [CA3935] 1466
Failure Code [CA3936] 1468
Failure Code [CA4151] 1470
Failure Code [CA4152] 1474
Failure Code [CA4155] 1478
Failure Code [CA4156] 1480
Failure Code [CA4157] 1483
Failure Code [CA4158] 1485
Failure Code [CA4159] 1486
Failure Code [CA4161] 1487
Failure Code [CA4162] 1490
Failure Code [CA4163] 1493
Failure Code [CA4164] 1494
Failure Code [CA4165] 1496
Failure Code [CA4166] 1498
Failure Code [CA4168] 1499
Failure Code [CA4169] 1502
Failure Code [CA4171] 1504
Failure Code [CA4249] 1507
Failure Code [CA4251] 1509
Failure Code [CA4259] 1511
Failure Code [CA4261] 1514
Failure Code [CA4277] 1517
Failure Code [CA4281] 1520
Failure Code [CA4459] 1523
Failure Code [CA4461] 1525
Failure Code [CA4658] 1528
Failure Code [CA4731] 1532
Failure Code [CA4732] 1533
Failure Code [CA4739] 1534
Failure Code [CA4768] 1535
Failure Code [CA4769] 1537
Failure Code [CA4842] 1540
Failure Code [CA4952] 1544
Failure Code [CA5115] 1546
Failure Code [CA5179] 1549
Failure Code [CA5181] 1551
Failure Code [CA5383] 1553
Failure Code [D110KB] 1555
Failure Code [D19JKZ] 1557
Failure Code [D811MC] 1560
Failure Code [D862KA] 1561
Failure Code [D8ALKA] 1563
Failure Code [D8ALKB] 1566
Failure Code [D8AQKR] 1568
Failure Code [D8G1KT] 1575
Failure Code [D8G6KT] 1576
Failure Code [DA20MC] 1577
Failure Code [DA22KK] 1578
Failure Code [DA25KP] 1581
Failure Code [DA26KP] 1584
Failure Code [DA29KQ] 1587
Failure Code [DA2LKA] 1589
Failure Code [DA2LKB] 1592
Failure Code [DA2QKR] 1594
Failure Code [DA2RKR] 1603
Failure Code [DAF0MB] 1604
Failure Code [DAF0MC] 1605
Failure Code [DAF8KB] 1606
Failure Code [DAF9KQ] 1608
Failure Code [DAFGMC] 1609
Failure Code [DAFLKA] 1610
Failure Code [DAFLKB] 1613
Failure Code [DAFQKR] 1615
Failure Code [DAZ9KQ] 1623
Failure Code [DAZQKR] 1624
Failure Code [DB2QKR] 1631
Failure Code [DB2RKR] 1639
Failure Code [DBP0KM] 1644
Failure Code [DBP0KT] 1645
Failure Code [DBP5KB] 1646
Failure Code [DBP5KY] 1649
Failure Code [DBPQKR] 1652
Failure Code [DDNRKA] 1660
Failure Code [DDNRKY] 1662
Failure Code [DDNS00] 1664
Failure Code [DGH2KA] 1666
Failure Code [DGH2KB] 1668
Failure Code [DHA4KA] 1670
Failure Code [DHAAMA] 1672
Failure Code [DHACMA] 1674
Failure Code [DHPAMA] 1676
Failure Code [DHPBMA] 1679
Failure Code [DHS3MA] 1682
Failure Code [DHS4MA] 1685
Failure Code [DHS8MA] 1688
Failure Code [DHS9MA] 1691
Failure Code [DHSAMA] 1694
Failure Code [DHSBMA] 1697
Failure Code [DHSCMA] 1700
Failure Code [DHSDMA] 1703
Failure Code [DHSFMA] 1706
Failure Code [DHSGMA] 1709
Failure Code [DHSHMA] 1712
Failure Code [DHSJMA] 1715
Failure Code [DKR0MA] 1718
Failure Code [DKR1MA] 1721
Failure Code [DKULKA] 1724
Failure Code [DKULKB] 1726
Failure Code [DKULKY] 1728
Failure Code [DLM5KA] 1730
Failure Code [DLM5MB] 1732
Failure Code [DR10KA] 1734
Failure Code [DR12KA] 1737
Failure Code [DR20KA] 1739
Failure Code [DR21KX] 1741
Failure Code [DR30KA] 1743
Failure Code [DR31KX] 1745
Failure Code [DR40KA] 1747
Failure Code [DUMBKA] 1749
Failure Code [DUMBKB] 1752
Failure Code [DV20KB] 1754
Failure Code [DW43KA] 1756
Failure Code [DW43KB] 1758
Failure Code [DW43KY] 1760
Failure Code [DW45KA] 1762
Failure Code [DW45KB] 1765
Failure Code [DW45KY] 1768
Failure Code [DW4CKY] 1770
Failure Code [DW91KA] 1772
Failure Code [DW91KB] 1774
Failure Code [DW91KY] 1776
Failure Code [DWA2KA] 1778
Failure Code [DWA2KB] 1780
Failure Code [DWA2KY] 1782
Failure Code [DWK0KA] 1784
Failure Code [DWK0KB] 1786
Failure Code [DWK0KY] 1788
Failure Code [DWK2KA] 1790
Failure Code [DWK2KB] 1792
Failure Code [DWK2KY] 1794
Failure Code [DWK8KA] 1796
Failure Code [DWK8KB] 1798
Failure Code [DWK8KY] 1800
Failure Code [DWN5KA] 1802
Failure Code [DWN5KB] 1804
Failure Code [DWN5KY] 1806
Failure Code [DWPUKA] 1808
Failure Code [DWPUKB] 1810
Failure Code [DWPUKY] 1812
Failure Code [DXA8KA] 1814
Failure Code [DXA8KB] 1816
Failure Code [DXA9KA] 1818
Failure Code [DXA9KB] 1820
Failure Code [DXE0KA] 1822
Failure Code [DXE0KB] 1824
Failure Code [DXE4KA] 1826
Failure Code [DXE4KB] 1828
Failure Code [DXE4KY] 1830
Failure Code [DXE5KA] 1832
Failure Code [DXE5KB] 1834
Failure Code [DXE6KA] 1836
Failure Code [DXE6KB] 1838
Failure Code [DXE7KA] 1840
Failure Code [DXE7KB] 1842
Failure Code [DXE7KY] 1844
Failure Code [DXE8KA] 1846
Failure Code [DXE8KB] 1848
Failure Code [DXE8KY] 1850
Failure Code [DXE9KA] 1852
Failure Code [DXE9KB] 1854
Failure Code [DXE9KY] 1856
Failure Code [DXEAKA] 1858
Failure Code [DXEAKB] 1860
Failure Code [DXEAKY] 1862
Failure Code [DXEKKA] 1864
Failure Code [DXEKKB] 1866
Failure Code [DXEKKY] 1868
Failure Code [DXELKA] 1870
Failure Code [DXELKB] 1872
Failure Code [DXELKY] 1874
Failure Code [DY20KA] 1876
Failure Code [DY20MA] 1878
Failure Code [DY2CKB] 1880
Failure Code [DY2DKB] 1883
Failure Code [DY2EKB] 1885
Failure Code [F311KA] 1887
Failure Code [F311KB] 1889
Failure Code [F312KA] 1891
Failure Code [F312KB] 1893
Failure Code [F313KA] 1895
Failure Code [F313KB] 1897
Failure Code [F314KA] 1900
Failure Code [F314KB] 1902
Failure Code [F315KB] 1904
Failure Code [F315KY] 1906
Failure Code [F316KB] 1908
Failure Code [F316KY] 1910
Failure Code [F318KB] 1912
Failure Code [F318KY] 1915
Failure Code [F31AKB] 1917
Failure Code [F31AKY] 1919
Failure Code [F31BKB] 1921
Failure Code [F31BKY] 1923
Failure Code [F31CKB] 1925
Failure Code [F31CKY] 1927
Failure Code [F31DKB] 1929
Failure Code [F31DKY] 1931
Failure Code [F31EKB] 1933
Failure Code [F31EKY] 1935
Troubleshooting of Electrical System (E-Mode) 1937
E-1 Engine Does Not Start (Engine Does Not Crank) 1937
E-2 Manual Preheating System Does Not Operate 1943
E-3 Automatic Preheating System Does Not Operate 1946
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1948
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1950
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1953
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1954
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1955
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1956
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1957
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1958
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1959
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1960
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1961
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1962
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1963
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1964
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1966
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1967
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1968
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1969
E-23 Some Areas of Machine Monitor Screen are Not Shown 1970
E-24 Function Switch Does Not Operate 1971
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1972
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1973
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1974
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1975
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1976
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1977
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1978
E-32 Alarm Buzzer Cannot be Canceled 1980
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1981
E-34 Service Mode Cannot be Selected 1982
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1983
E-36 All Work Equipment, Swing and Travel Do Not Lock 1986
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1988
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1991
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1993
E-40 One-Touch Power Maximizing Function is Not Cancelled 1996
E-41 Alarm Does Not Sound During Travel 1997
E-42 Alarm Does Not Stop When Machine Stops 1999
E-43 Horn Does Not Sound 2000
E-44 Horn Does Not Stop 2003
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 2005
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2006
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 2008
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2009
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2010
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 2011
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 2012
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2013
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2014
E-54 “Swing” is Not Shown Correctly with Monitoring Function 2015
E-55 “Travel” is Not Shown Correctly with Monitoring Function 2016
E-56 Service is Not Shown Correctly with Monitoring Function 2017
E-57 Attachment Hydraulic Circuit Cannot be Changed 2019
E-58 KOMTRAX System Does Not Operate Correctly 2020
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2021
Information Shown in Troubleshooting Table (H-Mode) 2021
System Chart of Hydraulic and Mechanical Systems 2022
Failure Mode and Cause Table 2024
H-1 All Work Equipment, Swing and Travel Do Not Work 2033
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2034
H-3 Fine Control Performance or Response is Unsatisfactory 2037
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2038
H-5 Engine Speed Drops Largely or Engine Stops 2039
H-6 Speed or Power of Boom is Low 2041
H-7 Arm Speed or Power is Low 2045
H-8 Bucket Speed or Power is Low 2050
H-9 Work Equipment Does Not Move in Single Operation 2053
H-10 Hydraulic Drift of Boom is Large 2054
H-11 Hydraulic Drift of Arm is Large 2056
H-12 Hydraulic Drift of Bucket is Large 2058
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2059
H-14 Time Lag of Work Equipment is Large 2060
H-15 One-Touch Power Maximizing Function Does Not Operate 2061
H-16 Attachment Circuit Cannot be Changed 2062
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2063
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2064
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2065
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 2066
H-21 Machine Does Not Travel Straight 2067
H-22 Machine is Not Steered Correctly or Steering Power is Low 2069
H-23 Travel Speed is Low 2072
H-24 One of Tracks Does Not Run 2074
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2075
H-26 Upper Structure Does Not Swing to Right and Left 2076
H-27 Upper Structure Swings Only to Right or Left 2077
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 2078
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2079
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2080
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2081
H-32 Shock is Large When Upper Structure Stops Swing Operation 2082
H-33 There is Large Unusual Noise When It Stops Swing Operation 2083
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2084
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2085
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2086
H-37 Unusual Noise is Heard from Around Fan 2087
Troubleshooting of Engine (S-Mode) 2088
Information Shown in Troubleshooting Table (S-Mode) 2088
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2089
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2090
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2091
S-4 Engine Startability is Unsatisfactory 2093
S-5 Engine Does Not Pick Up Smoothly 2095
S-6 Engine Stops During Operation 2097
S-7 Engine Runs Rough or is Not Stable 2099
S-8 Engine Lacks Power 2100
S-9 KDPF Becomes Clogged in a Short Time 2102
S-10 Engine Oil Consumption is Excessive 2104
S-11 Oil Becomes Dirty Quickly 2105
S-12 Fuel Consumption is Excessive 2106
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2107
S-14 Oil Pressure Drops 2108
S-15 Fuel Mixes Into Engine Oil 2110
S-16 Water Mixes Into Engine Oil (Milky) 2111
S-17 Coolant Temperature Increases Too High (Overheating) 2112
S-18 Unusual Noise is Heard 2113
S-19 Vibration is Excessive 2114
S-20 Air Cannot be Bled from Fuel Circuit 2115
S-21 Active Regeneration is Done Frequently 2116
S-22 Active Regeneration Continues Long 2118
S-23 White Smoke is Exhausted During Active Regeneration 2119
S-24 DEF Consumption is Excessive 2120
S-25 There is Unusual Smell (Irritating Odor) 2122
S-26 Foreign Materials Enter DEF (DEF Increases) 2123
50 Disassembly and Assembly 2125
Table of Contents 2126
Precautions Before Work 2131
Related Information on Disassembly and Assembly 2132
How to Read This Manual 2132
Coating Materials List 2133
Special Tool List 2138
Sketches of Special Tools 2150
Engine and Cooling System 2156
Remove and Install Supply Pump Assembly 2156
Remove Supply Pump Assembly 2156
Install Supply Pump Assembly 2159
Remove and Install Injector Assembly 2162
How to Remove Injector Assembly 2162
How to Install Injector Assembly 2167
Remove and Install Cylinder Head Assembly 2175
How to Remove Cylinder Head Assembly 2176
How to Install Cylinder Head Assembly 2185
Remove and Install EGR Valve Assembly 2201
Remove EGR Valve Assembly 2201
Install EGR Valve Assembly 2202
Remove and Install EGR Cooler Assembly 2204
How to Remove EGR Cooler Assembly 2204
How to Install EGR Cooler Assembly 2208
Remove and Install Starter Assembly 2213
Remove Starting Motor Assembly 2213
Install Starting Motor Assembly 2214
Remove and Install Alternator Belt 2217
Remove Alternator Belt 2217
Install Alternator Belt 2219
Remove and Install Radiator Assembly 2222
How to Remove Radiator Assembly 2222
How to Install Radiator Assembly 2224
Remove and Install Hydraulic Oil Cooler Assembly 2227
How to Remove Hydraulic Oil Cooler Assembly 2227
How to Install Hydraulic Oil Cooler Assembly 2230
Remove and Install Aftercooler Assembly 2233
Remove Aftercooler Assembly 2233
Install Aftercooler Assembly 2235
Remove and Install Fan Clutch Assembly 2237
How to Remove Fan Clutch Assembly 2237
How to Install Fan Clutch Assembly 2242
Remove and Install Fan 2246
Remove Fan 2246
Install Fan 2246
Remove and Install Engine and Main Pump Assembly 2247
Remove Engine and Main Pump Assembly 2247
Install Engine and Main Pump Assembly 2256
Remove and Install Engine Front Oil Seal 2268
How to Remove Engine Front Oil Seal 2268
How to Install Engine Front Oil Seal 2271
Remove and Install Engine Rear Oil Seal 2275
How to Remove Engine Rear Oil Seal 2275
How to Install Engine Rear Oil Seal 2276
Remove and Install Fuel Cooler Assembly 2279
Remove Fuel Cooler Assembly 2279
Install Fuel Cooler Assembly 2279
Remove and Install Engine Hood Assembly 2281
How to Remove Engine Hood Assembly 2281
How to Install Engine Hood Assembly 2283
Remove and Install Fuel Tank Assembly 2288
Remove Fuel Tank Assembly 2288
Install Fuel Tank Assembly 2292
Remove and Install DEF Tank Assembly 2298
How to Remove DEF Tank Assembly 2298
How to Install DEF Tank Assembly 2303
Remove and Install DEF Tank Sensor Flange Assembly 2309
How to Remove DEF Tank Sensor Flange Assembly 2309
How to Install DEF Tank Sensor Flange Assembly 2315
Remove and Install DEF Tank Sensor 2321
Remove DEF Tank Sensor 2321
Install DEF Tank Sensor 2321
Remove and Install DEF Tank Strainer 2328
Remove DEF Tank Strainer 2328
Install DEF Tank Strainer 2328
Remove and Install DEF Tank Filler Port Filter 2329
Remove DEF Tank Filler Port Filter 2329
Install DEF Tank Filler Port Filter 2331
Remove and Install KDPF Assembly 2334
How to Remove KDPF Assembly 2334
How to Install KDPF Assembly 2336
Disassemble and Assemble KDPF Assembly 2338
Disassemble KDPF Assembly 2339
Assemble KDPF Assembly 2342
Remove and Install SCR Assembly 2347
How to Remove SCR Assembly 2347
How to Install SCR Assembly 2349
Remove and Install KDPF and SCR Assembly 2351
How to Remove KDPF and SCR Assembly 2351
Install KDPF and SCR Assembly 2358
Remove and Install KDPF and SCR Assembly Bracket 2364
Remove KDPF and SCR Assembly Bracket 2364
Install KDPF and SCR Assembly Bracket 2371
Remove and Install Bellows Pipe Assembly 2378
How to Remove Bellows Pipe Assembly 2378
How to Install Bellows Pipe Assembly 2380
Remove and Install KCCV Assembly 2384
Remove KCCV Assembly 2384
Install KCCV Assembly 2386
Remove and Install DEF Mixing Tube 2391
Remove DEF Mixing Tube 2391
Install DEF Mixing Tube 2397
Remove and Install DEF Injector 2403
Remove DEF Injector 2403
Install DEF Injector 2406
Remove and Install DEF Pump 2409
Remove DEF Pump 2409
Install DEF Pump 2412
Remove and Install DEF Hose 2415
Remove DEF Hose 2415
Install DEF Hose 2423
Remove and Install Air Cleaner Assembly 2429
Remove Air Cleaner Assembly 2429
Install Air Cleaner Assembly 2430
Remove and Install Air Conditioner Compressor Assembly 2432
Remove Air Conditioner Compressor Assembly 2432
How to Install Air Conditioner Compressor Assembly 2434
Remove and Install Air Conditioner Condenser Assembly 2437
How to Remove Air Conditioner Condenser Assembly 2437
How to Install Air Conditioner Condenser Assembly 2438
Power Train 2439
Remove and Install Travel Motor and Final Drive Assembly 2439
Remove Travel Motor and Final Drive Assembly 2439
Install Travel Motor and Final Drive Assembly 2440
Disassemble and Assemble Final Drive Assembly 2442
Disassemble Final Drive Assembly 2442
Assemble Final Drive Assembly 2446
Remove and Install Swing Motor and Swing Machinery Assembly 2455
Remove Swing Motor and Swing Machinery Assembly 2455
Install Swing Motor and Swing Machinery Assembly 2457
Disassemble and Assemble Swing Machinery Assembly 2461
Disassemble Swing Machinery Assembly 2461
Assemble Swing Machinery Assembly 2465
Remove and Install Swing Circle Assembly 2472
Remove Swing Circle Assembly 2472
Install Swing Circle Assembly 2472
Undercarriage and Frame 2474
Separate and Connect Track Assembly 2474
Separate Track Assembly 2474
Install Track Assembly 2476
Remove and Install Sprocket 2479
Remove Sprocket 2479
Install Sprocket 2479
Remove and Install Idler and Idler Cushion Assembly 2481
Remove Idler and Idler Cushion Assembly 2481
Install Idler and Idler Cushion Assembly 2482
Disassemble and Assemble Idler Assembly 2483
Disassemble Idler Assembly 2483
Assemble Idler Assembly 2484
Disassemble and Assemble Idler Cushion Assembly 2488
Disassemble Idler Cushion Assembly 2489
Assemble Idler Cushion Assembly 2489
Disassemble and Assemble Track Roller Assembly 2491
Disassemble Track Roller Assembly 2492
Assemble Track Roller Assembly 2493
Disassemble and Assemble Carrier Roller Assembly 2495
Disassemble Carrier Roller Assembly 2495
Assemble Carrier Roller Assembly 2497
Remove and Install Revolving Frame Assembly 2499
Remove Revolving Frame Assembly 2499
Install Revolving Frame Assembly 2501
Remove and Install Counterweight Assembly 2504
Remove Counterweight Assembly 2504
Install Counterweight Assembly 2507
Hydraulic System 2511
Remove and Install Center Swivel Joint Assembly 2511
Remove Center Swivel Joint Assembly 2511
Install Center Swivel Joint Assembly 2513
Disassemble and Assemble Center Swivel Joint Assembly 2516
Disassemble Center Swivel Joint Assembly 2516
Assemble Center Swivel Joint Assembly 2517
Remove and Install Hydraulic Tank Assembly 2519
Remove Hydraulic Tank Assembly 2519
How to Install Hydraulic Tank Assembly 2522
Remove and Install Main Pump Assembly 2526
Remove Main Pump Assembly 2526
Install Main Pump Assembly 2529
Remove and Install Control Valve Assembly 2533
How to Remove Control Valve Assembly 2533
How to Install Control Valve Assembly 2540
Disassemble and Assemble Control Valve Assembly 2548
Replace Pressure Compensation Valve Seal Ring 2548
Assemble Control Valve Assembly 2549
Disassemble and Assemble Work Equipment PPC Valve Assembly 2553
Disassemble Work Equipment PPC Valve Assembly 2553
How to Assemble Work Equipment PPC Valve Assembly 2553
Disassemble and Assemble Travel PPC Valve Assembly 2555
Disassemble Travel PPC Valve Assembly 2555
How to Assemble Travel PPC Valve Assembly 2556
Work Equipment 2558
Remove and Install Work Equipment Assembly 2558
Remove Work Equipment Assembly 2558
Install Work Equipment Assembly 2562
Remove and Install Boom Anti-drop Valve Assembly 2567
Remove Boom Anti-drop Valve Assembly 2567
Install Boom Anti-drop Valve Assembly 2569
Remove and Install Arm Anti-Drop Valve Assembly 2570
Remove Arm Anti-Drop Valve Assembly 2570
Install Arm Anti-Drop Valve Assembly 2572
Disassemble and Assemble Anti-Drop Valve Assembly 2573
Disassemble Anti-Drop Valve Assembly 2573
Assemble Anti-Drop Valve Assembly 2573
Disassemble and Assemble Work Equipment Cylinder Assembly 2574
How to Disassemble Work Equipment Cylinder Assembly 2574
How to Assemble Work Equipment Cylinder Assembly 2577
CAB Related Parts 2583
Remove and Install Operator Cab Assembly 2583
How to Remove Operator Cab Assembly 2583
Install Operator CAB Assembly 2591
Remove and Install Operator Cab Glass (Adhered Glass) 2598
Remove Operator CAB Glass (Adhered Glass) 2600
Install Operator CAB Glass (Adhered Glass) 2600
Remove and Install Front Window Assembly 2610
Remove Front Window Assembly 2610
Install Front Window Assembly 2613
Remove and Install Floor Frame Assembly 2619
How to Remove Floor Frame Assembly 2619
How to Install Floor Frame Assembly 2626
Remove and Install Air Conditioner Unit Assembly 2633
Remove Air Conditioner Unit Assembly 2633
Install Air Conditioner Unit Assembly 2639
Remove and Install Operator Seat 2646
Remove Operator’s Seat 2646
Install Operator’s Seat 2648
How to Remove and Install Seat Belt 2651
How to Remove Seat Belt 2651
How to Install Seatbelt 2652
Remove and Install Work Equipment Control Lever Assembly 2653
How to Remove Work Equipment Control Lever Assembly 2653
How to Install Work Equipment Control Lever Assembly 2659
Remove and Install Front Wiper Assembly 2668
Remove Front Wiper Assembly 2668
Install Front Wiper Assembly 2673
Electrical System 2682
Remove and Install Engine Controller Assembly 2682
Remove Engine Controller Assembly 2682
Install Engine Controller Assembly 2683
Remove and Install Pump Controller Assembly 2685
Remove Pump Controller Assembly 2685
Install Pump Controller Assembly 2689
Remove and Install KomVision Controller Assembly 2694
Remove KomVision Controller Assembly 2694
Install KomVision Controller Assembly 2695
Remove and Install Machine Monitor Assembly 2696
Remove Machine Monitor Assembly 2696
Install Machine Monitor Assembly 2699
Remove and Install Pump Swash Plate Sensor 2703
Remove Pump Swash Plate Sensor 2703
Install Pump Swash Plate Sensor 2704
Remove and Install Mass Air Flow and Temperature Sensor 2705
How to Remove Mass Air Flow and Temperature Sensor 2705
How to Install Mass Air Flow and Temperature Sensor 2705
Remove and Install KCCV Crankcase Pressure Sensor 2707
How to Remove KCCV Crankcase Pressure Sensor 2707
How to Install KCCV Crankcase Pressure Sensor 2708
Remove and Install SCR Temperature Sensor 2709
Remove SCR Temperature Sensor 2709
Install SCR Temperature Sensor 2711
Remove and Install KomVision Camera 2714
Remove KomVision Camera 2714
Install KomVision Camera 2715
Remove and Install Gateway Function Controller Assembly 2717
Remove Gateway Function Controller Assembly 2717
How to Install Gateway Function Controller Assembly 2722
Remove and Install Communication Terminal Wiring Harness 2727
Remove Communication Terminal Wiring Harness 2727
Install Communication Terminal Wiring Harness 2735
Remove and Install Communication Terminal 2744
Remove Communication Terminal 2744
Install Communication Terminal 2746
60 Maintenance Standard 2749
Table of Contents 2750
Engine and Cooling System 2751
Maintenance Standard for Engine Mount 2751
Maintenance Standard for Cooling System 2752
Power Train 2754
Maintenance Standard for Swing Circle 2754
Maintenance Standard for Swing Machinery 2755
Maintenance Standard for Final Drive 2757
Maintenance Standard for Sprocket 2759
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2760
Undercarriage and Frame 2761
Maintenance Standard for Track Frame and Idler Cushion 2761
Maintenance Standard for Idler 2763
Maintenance Standard for Track Roller 2765
Maintenance Standard for Carrier Roller 2766
Maintenance Standard for Track Shoes 2767
Maintenance Standard for Triple Shoes 2770
Maintenance Standard for Swamp Shoes 2771
Maintenance Standard for Road Liner 2772
Hydraulic System 2773
Maintenance Standard for Hydraulic Tank 2773
Maintenance Standard for Main Pump 2774
Maintenance Standard for LS-EPC Valve 2775
Maintenance Standard for PC-EPC Valve 2776
Maintenance Standard for Swing Motor 2777
Maintenance Standard for Travel Motor 2780
Maintenance Standard for Control Valve 2783
Maintenance Standard for Boom Anti-Drop Valve 2793
Maintenance Standard for Arm Anti-Drop Valve 2795
Maintenance Standard for Work Equipment and Swing PPC Valve 2797
Maintenance Standard for Travel PPC Valve 2800
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2803
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2804
Maintenance Standard for 2nd-Line Attachment PPC Valve 2806
Maintenance Standard for Solenoid Valve 2808
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2809
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2810
Maintenance Standard for Center Swivel Joint 2811
Work Equipment 2812
Maintenance Standard for Work Equipment Linkage 2812
Dimensions of Arm 2817
Dimensions of Bucket 2819
Maintenance Standard for Boom Cylinder (Large Diameter Piston) 2821
Maintenance Standard for Arm Cylinder 2822
Maintenance Standard for Bucket Cylinder 2823
80 Appendix 2825
Table of Contents 2826
Precautions Before Work 2828
Air Conditioner System 2829
Precautions for Refrigerant 2829
Air Conditioner Component 2830
Specifications of Air Conditioner 2832
Structure and Function of Refrigeration Cycle 2833
Outline of Refrigeration Cycle 2834
Component Parts of Air Conditioner System 2836
Air Conditioner Unit 2836
Configuration Diagram of Air Conditioner Unit 2836
Function of Air Conditioner Unit 2838
Component Parts of Air Conditioner Unit 2840
Function of Evaporator as Air Conditioner Unit Component 2841
Function of Heater Core as Air Conditioner Unit Component 2841
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2841
Function of Servo Motor as Air Conditioner Unit Component 2841
Structure of Expansion Valve as Air Conditioner Unit Component 2842
Function of Expansion Valve as Air Conditioner Unit Component 2842
Operate Expansion Valve as Air Conditioner Unit Component 2842
Function of Dual Pressure Switch 2843
Air Conditioner Controller 2844
Structure of Air Conditioner Controller 2844
Compressor 2845
Structure of Compressor 2845
Specifications of Compressor 2845
Function of Compressor 2845
Condenser 2846
Structure of Condenser 2846
Specifications of Condenser 2846
Function of Condenser 2846
Air Conditioner Related Sensors 2848
Structure of Sunlight Sensor 2848
Function of Sunlight Sensor 2848
Structure of Outside Temperature Sensor 2848
Function of Outside Air Temperature Sensor 2848
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2850
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2852
System Diagram of Air Conditioner 2854
Input and Output Signals of Air Conditioner Controller 2855
Function of Air Conditioner Controller 2856
Locations of Air Conditioner Parts and Layout of Connectors 2857
Examine Air Leakage (Duct) 2861
How to Examine Air Leakage (Duct) 2861
Examine Air Conditioner with Self-Diagnosis Function 2863
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2864
Examine Vent (Mode) Changeover 2865
How to Examine Vent (Mode) Changeover 2865
Examine Fresh/Recirc Air Changeover 2867
How to Examine Fresh/Recirc Air Changeover 2867
Examine Sunlight Sensor 2868
How to Examine Sunlight Sensor 2868
Examine Refrigerant (Dual) Pressure Switch 2869
How to Examine Refrigerant (Dual) Pressure Switch 2869
Examine Relay 2870
How to Examine Relay 2870
Air Conditioner Troubleshooting Chart 1 2871
Air Conditioner Troubleshooting Chart 2 2872
Information Shown in Troubleshooting Table 2875
Failure Code [879AKA] 2876
Failure Code [879AKB] 2877
Failure Code [879BKA] 2878
Failure Code [879BKB] 2880
Failure Code [879CKA] 2882
Failure Code [879CKB] 2883
Failure Code [879DKZ] 2884
Failure Code [879EMC] 2886
Failure Code [879FMC] 2887
Failure Code [879GKX] 2888
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2890
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2892
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2895
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2897
Troubleshooting by Gauge Pressure 2899
Connect Service Tool 2902
How to Connect Service Tool 2902
Precautions for Disconnection and Connection of Air Conditioner Piping 2904
Handle Compressor Oil 2906
Replace Desiccant 2908
90 Circuit Diagrams 2911
Table of Contents 2912
Hydraulic Circuit Diagram 2913
Symbols Used in Hydraulic Circuit Diagram 2913
Hydraulic Circuit Diagram 2917
Electrical Circuit Diagram 2919
Symbols Used in Electric Circuit Diagram 2919
Electrical Circuit Diagram (1/9) 2923
Electrical Circuit Diagram (2/9) 2925
Electrical Circuit Diagram (3/9) 2927
Electrical Circuit Diagram (4/9) 2929
Electrical Circuit Diagram (5/9) 2931
Electrical Circuit Diagram (6/9) 2933
Electrical Circuit Diagram (7/9) 2935
Electrical Circuit Diagram (8/9) 2937
Electrical Circuit Diagram (9/9) 2939
Index 2941

S.V  21/12/24