Komatsu PC210LC-11E0 Excavator Shop Manual SEN06965-00 PDF

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Komatsu PC210LC-11E0 Excavator Shop Manual SEN06965-00 – PDF DOWNLOAD

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Komatsu PC210LC-11E0 Excavator Shop Manual SEN06965-00 – PDF DOWNLOAD 

Language : English
Pages : 2940
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC210LC-11E0 Excavator Shop Manual SEN06965-00 – PDF DOWNLOAD 

SERIAL NUMBERS 508570 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

TABLE OF CONTENTS:

Komatsu PC210LC-11E0 Excavator Shop Manual SEN06965-00 – PDF DOWNLOAD 

SERIAL NUMBERS 508570 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
How to Examine Engine Type 39
Precautions for DEF 41
General Character and Precautions for Handling 41
Precautions When You Add 41
Precautions for Storage 41
Precautions for Fire Hazard and Leakage 41
Other Precautions 41
Store DEF 41
Precautions When You Handle Hydraulic Equipment 43
Precautions When You Disconnect and Connect Pipings 46
Precautions When You Handle Electrical Equipment 53
Precautions When You Handle Fuel System Equipment 55
Precautions When You Handle Intake System Equipment 56
Practical Use of KOMTRAX 57
Disconnect and Connect Push-Pull Type Coupler 58
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 60
Precautions for Disconnection and Connection of Connectors 62
Disconnect and Connect Deutsch Connector 66
How to Disconnect and Connect Slide Lock Type Connector 67
Disconnect and Connect Connector with Lock to Pull 69
Disconnect and Connect Connector with Lock to Push 70
Disconnect and Connect Connector with Housing to Rotate 72
How to Read the Codes for Electric Cable 73
Explanation of Terms for Maintenance Standard 77
Standard Tightening Torque Table 80
Conversion Table 87
01 Specification 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: PC210LC-11E0 95
Working Range Drawings 97
Working Range: PC210LC-11E0 97
Specifications 98
Specifications: PC210LC-11E0 98
Weight Table 101
Weight Table: PC210LC-11E0 101
Fuel, Coolant, Lubricant 103
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 103
10 Structure and Function 105
Table of Contents 106
Urea SCR System 109
Layout Drawing of Urea SCR System 110
Urea SCR System Diagram 115
Function of Urea SCR System 116
Function of DEF System 116
Inducement Strategy 118
Component Parts of Urea SCR System 126
DEF Mixing Tube 126
SCR Assembly 127
DEF Tank 129
DEF Pump 131
DEF Injector 132
DEF Hose 133
DEF Tank Heating Valve 134
Boot-up System 135
Layout Drawing of Boot-up System 135
System Operating Lamp System 137
System Diagram of System Operating Lamp 137
Function of Operation Lamp System 137
Operation of System Operating Lamp System 137
Battery Disconnect Switch 138
Function of Battery Disconnect Switch 138
Engine System 139
Layout Drawing of Engine System 139
Specifications of Engine System 140
Function of Engine System 140
Engine Control System 141
System Diagram of Engine Control 141
Operation of Engine Control System 142
Auto-Deceleration System 144
System Diagram of Auto-Deceleration System 144
Function of Auto-Deceleration System 144
Operation of Auto-Deceleration System 145
Engine Automatic Warm-up System 146
System Diagram of Engine Automatic Warm-up System 146
Function of Engine Automatic Warm-up System 147
Overheat Prevention System 148
Overheat Prevention System Diagram 148
Function of Overheat Prevention System 149
Turbocharger Protection System 151
System Diagram of Turbocharger Protection System 151
Function of Turbocharger Protection System 152
Component Parts of Engine System 153
VGT 153
EGR System 158
EGR Valve 160
EGR Cooler 162
KCCV System 164
KCCV Ventilator 166
KDPF 168
Cooling System 172
Layout Drawing of Cooling System 172
Specifications of Cooling System 173
Fan Speed Control System of Fan Clutch 174
Fan Speed Control System Diagram of Fan Clutch 174
Function of Fan Speed Control System of Fan Clutch 175
Engine Output Control System of Fan Clutch 176
Engine Output Control System Diagram of Fan Clutch 176
Function of Engine Output Control System of Fan Clutch 176
Component Parts of Cooling System 178
Fan Clutch 178
Control System 179
Layout Drawing of Control System 179
Machine Monitor System 182
System Diagram of Machine Monitor System 182
Function of Machine Monitor System 183
KomVision System 184
Layout Drawing of KomVision System 184
System Diagram of KomVision System 186
Function of KomVision System 186
KOMTRAX System 188
System Diagram of KOMTRAX System 188
Function of KOMTRAX System 188
Component Parts of Control System 189
Machine Monitor 189
KomVision Controller 204
KomVision Camera 208
Gateway Function Controller 209
Communication Terminal 212
Pump Controller 214
Resistor for PC-EPC Valve 218
CAN Terminating Resistor 219
Engine Controller 220
Fuel Control Dial 227
Hydraulic System 229
Layout Drawing of Hydraulic System 229
CLSS 235
Structure of CLSS 235
Operation of Unload Valve and LS Pressure 237
Pump Swash Plate Angle (Oil Flow) Control 238
Pressure Compensation Control 254
Engine and Pump Combined Control System 257
Engine and Pump Combined Control System Diagram 257
Function of Engine and Pump Combined Control System 258
Pump and Valve Control System 263
Pump and Valve Control System Diagram 263
Function of Pump and Valve Control System 264
Component Parts of Hydraulic System 266
Hydraulic Tank 266
Main Pump 268
Pilot Oil Filter 294
Control Valve 295
Work Equipment System 357
Layout Drawing of Work Equipment System 357
Structure of Valve Control 362
One-Touch Power Maximizing System 364
System Diagram of One-Touch Power Maximizing System 364
Function of One-Touch Power Maximizing System 365
PPC Lock System 366
System Diagram of PPC Lock 366
Function of PPC Lock System 366
Work Equipment and Travel Automatic Lock System 367
System Diagram of Lock Lever Automatic Lock System 367
Function of Work Equipment and Travel Automatic Lock System 367
Operation of Lock Lever Automatic Lock System 368
Attachment Oil Flow Adjuster System 369
Attachment Oil Flow Adjuster System Diagram 369
Function of Attachment Oil Flow Adjuster System 370
Tool Control System 371
Tool Control System Diagram 371
Component Parts of Work Equipment System 373
Work Equipment and Swing PPC Valve 373
1st-Line Attachment PPC Valve (with EPC Valve) 380
2nd-Line Attachment PPC Valve 388
Solenoid Valve 390
Boom Anti-drop Valve 393
Arm Anti-Drop Valve 397
Attachment Circuit Selector Valve (For High Pressure) 402
Attachment Circuit Selector Valve (For Low Pressure) 404
Pilot Circuit Accumulator 406
Attachment Circuit Accumulator 407
Swing System 408
Layout Drawing of Swing System 408
Swing Control System Diagram 412
Function of Swing Control System 412
Component Parts of Swing System 416
Swing Motor 416
Swing Machinery 428
Swing Circle 430
Travel System 431
Layout Drawing of Travel System 431
System Diagram of Travel Control System 435
Function of Travel Control System 436
Component Parts of Travel System 437
Travel Motor 437
Final Drive 449
Travel PPC Valve 452
Center Swivel Joint 456
Undercarriage and Frame 458
Layout Drawing of Undercarriage 458
Specifications of Undercarriage 459
Work Equipment 460
Structure of Work Equipment 460
Function of Work Equipment 460
Work Equipment Clearance Adjustment Shim 461
Function of Work Equipment Clearance Adjustment Shim 461
Bucket Clearance Adjustment Shim 461
Function of Bucket Clearance Adjustment Shim 461
CAB Related Parts 462
ROPS CAB 462
Structure of ROPS CAB 462
Function of ROPS CAB 462
CAB Mount 463
Structure of CAB Mount 463
Function of CAB Mount 463
CAB Tipping Stopper 464
Structure of CAB Tipping Stopper 464
Function of CAB Tipping Stopper 464
20 Standard Value Table 465
Table of Contents 466
Standard Value Table for Engine 467
Standard Value Table for Engine: PC210LC-11E0 467
Standard Value Table for Machine 471
Standard Value Table for Machine: PC210LC-11E0 471
Machine Posture and Procedures to Measure Performance 484
Standard Value Table for Electricity 488
Standard Value Table for Electricity 488
30 Testing and Adjusting 499
Table of Contents 500
Precautions Before Work 503
Related Information on Testing and Adjusting 504
Tools for Testing and Adjusting 504
Sketch of Tools for Testing and Adjusting 511
Engine and Cooling System 512
Examine Engine Speed 512
How to Examine Engine Speed 512
Examine Boost Pressure 515
How to Examine Boost Pressure on Machine Monitor 515
How to Examine Boost Pressure by Testing Tool 516
Examine Exhaust Gas Color 517
How to Examine Exhaust Gas Color with the Handy Smoke Checker 517
How to Examine Exhaust Gas Color with Smoke Meter 518
Examine Mass Air Flow and Temperature Sensor 520
How to Examine Mass Air Flow and Temperature Sensor 520
Examine and Adjust Valve Clearance 522
Check Valve Clearance 522
Adjust Valve Clearance 523
Examine Compression Pressure 525
How to Examine Compression Pressure 525
Examine Blowby Pressure 530
How to Examine Blowby Pressure 530
Examine Engine Oil Pressure 532
How to Examine Engine Oil Pressure 532
Examine EGR Valve and VGT Oil Pressure 533
How to Examine EGR Valve and VGT Oil Pressure 533
Examine Fuel Pressure 535
How to Examine Fuel Pressure 536
Examine Fuel Discharge, Return and Leakage 541
How to Examine Fuel Discharge, Return, and Leakage 542
Bleed Air from Fuel System 547
How to Bleed Air from Fuel System 547
Examine Fuel Circuit for Leakage 548
How to Examine Fuel System for Leakage 548
Handle Cylinder Cut-out Mode Operation 550
Handle No-Injection Cranking Operation 551
Examine and Adjust Air Conditioner Compressor Belt Tension 552
How to Examine Air Conditioner Compressor Belt 552
How to Adjust Air Conditioner Compressor Belt 552
Examine Fan Belt and Alternator Belt 554
How to Examine Fan Belt and Alternator Belt 554
Examine Automatic Tensioner 555
How to Examine Automatic Tensioner 555
How to Replace Fan Belt 556
Examine Cooling Fan Speed 557
How to Examine Cooling Fan Speed 557
Write Correction for Ash in Soot Accumulation to Engine Controller 558
How to Write Correction for Ash in Soot Accumulation to Engine Controller 558
Examine SCR Related Functions 559
Examine DEF Pump Raised Pressure 563
Examine Injection Volume from DEF Injector 566
Examine DEF Line Heater Relay 1 571
Examine DEF Line Heater Relay 2 574
Examine DEF Pump Heater Relay 577
Examine DEF Tank Heater Valve 580
Examine SCR Denitration Efficiency 583
Clean DEF Tank 587
How to Clean DEF Tank 587
Clean DEF Pump 591
How to Clean DEF Pump 591
Bleed Air from Coolant Circuit of DEF Tank 598
How to Bleed Air from Coolant Circuit of DEF Tank 598
Power Train 600
Examine Swing Circle Bearing Clearance 600
How to Examine Swing Circle Bearing Clearance 600
Undercarriage and Frame 601
Examine and Adjust Track Tension 601
How to Examine Track Tension 601
How to Adjust Track Tension 601
Hydraulic System 603
Release Remained Pressure in Hydraulic Circuit 603
How to Release Remained Pressure in Hydraulic System 603
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 604
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 605
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 611
Examine Oil Pressure of Control Circuit 614
Examine Oil Pressure in Control Circuit 614
Examine and adjust oil pressure in pump PC control circuit 616
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 616
Examine PC-EPC Valve Outlet Pressure 617
How to Adjust Oil Pressure in Pump PC Control Circuit 618
Examine and Adjust Oil Pressure in Pump LS Control Circuit 620
Examine LS Differential Pressure with Machine Monitor 620
Examine LS Differential Pressure by Testing Tool 621
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 624
How to Examine LS-EPC Valve Outlet Pressure 625
Adjust LS Valve 626
Examine Outlet Pressure of Solenoid Valve 627
How to Examine Outlet Pressure of Solenoid Valve 627
Operating Condition of Solenoid Valve 628
Examine PPC Valve Outlet Pressure 631
Examine Outlet Pressure in PPC Valve 631
Examine Attachment Circuit Oil Pressure 633
How to Examine Attachment Circuit Oil Pressure 633
Adjust Play of Work Equipment and Swing PPC Valves 634
How to Adjust Play of Work Equipment and Swing PPC Valves 634
Examine Pump Swash Plate Sensor 635
How to Examine pump swash plate sensor 635
Examine Parts Which Cause Hydraulic Drift of Work Equipment 636
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 636
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 636
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 637
Examine Oil Leakage 638
How to Examine Oil Leakage from Boom Cylinder 638
How to Examine Oil Leakage from Arm Cylinder 638
How to Examine Oil Leakage from Bucket Cylinder 639
How to Examine Oil Leakage from Swing Motor 640
How to Examine Oil Leakage from Travel Motor 640
Bleed Air from Hydraulic System 641
How to Bleed Air from Hydraulic System 643
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 645
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 645
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 649
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 649
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 653
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 653
CAB Related Parts 660
Examine CAB Tipping Stopper 660
How to Examine Cab Tipping Stopper 660
How to Adjust Mirrors 661
Procedure to Adjust Machine Left Front Mirror (A) 661
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 662
Procedure to Adjust Machine Right Front Mirror (B) 663
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 664
Procedure to Adjust Machine Right Side Mirror (C) 665
Electrical System 667
Set and Operate Machine Monitor 667
Operator Mode 671
Function to Show Technician Identification Status Screen 671
Function to Show Operator Identification Input Screen 671
Examine Function by LCD (Liquid Crystal Display) 672
Examine Function of Service Meter 672
Usage Limitation and Maintenance Password Change Function 672
Service Mode 675
How to See Pre-defined Monitoring Information 677
How to Examine Self-Define Monitor Information 684
Abnormality Record Menu 695
How to See Maintenance Record 699
Maintenance Mode Setting 700
Set Phone Number Entry 704
Default Menu 706
Diagnostic Tests Menu 718
Adjustment Menu 727
No-Injection Cranking Operation 746
Show Service Message 747
Start Up KOMTRAX System 749
Adjust Rearview Camera Angle 754
How to Adjust Rearview Camera Angle 754
Adjust KomVision Camera Angle 757
How to Adjust KomVision Camera Angle 758
Adjust KomVision Related Function 762
Setting of KomVision (Main Setting) 763
Setting of KomVision (Camera Setting) 765
Setting of KomVision (Camera Calibration) 768
KomVision screen – Check 12 m visibility 781
Set Region of Bluetooth(R) Compatible Radio 784
Set Region of Bluetooth(R) Compatible Radio 784
Handle Voltage Circuit of Engine Controller 786
Handle Battery Disconnect Switch 787
Examine Diodes 788
Examine Diodes by Digital Tester 788
How to Examine Diodes by Analog Tester 788
Pm Clinic 789
Pm Clinic Service 789
Pm Clinic Check Sheet 791
40 Troubleshooting 803
Table of Contents 804
Precautions Before Work 815
Related Information to Troubleshooting 816
General Troubleshooting Points 816
Troubleshooting Points for Urea SCR System 817
Sequence of Events in Troubleshooting 831
Checks Before Troubleshooting 833
Inspection Procedure Before Troubleshooting 835
Walk-Around Check 835
Test in Accordance with Testing Procedure 837
Examine Fuel Level and Type 837
Examine for Impure Ingredient in Fuel 837
Examine Fuel Prefilter 838
Examine Water Separator, Drain Water and Sediment 838
How to Replace Fuel Prefilter Cartridge 839
Examine Fuel Main Filter 840
Examine Engine Oil Level (Oil Quantity in Oil Pan) 842
Examine Coolant Level (Reservoir Tank) 843
Examine Air Cleaner Clogging 843
Clean Outer Element 844
Replace Element 846
Examine Hydraulic Oil Level 847
Examine Hydraulic Oil Strainer 848
Examine Hydraulic Oil Filter 849
Examine Oil Level in Swing Machinery Case 850
Examine Oil Level in Damper Case 851
Examine Oil Level in Final Drive Case 851
Bleed Air from Fuel System 852
Bleed Air from Hydraulic System 852
How to Examine Electric Equipment 852
Preparation for Troubleshooting of Electrical System 860
Procedure for Troubleshooting 873
Symptom and Troubleshooting Numbers 876
Information Shown in Troubleshooting Table 880
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 882
Connector List 885
Connector Layout (1) 893
Connector Layout (2) 895
Connector Layout (3) 897
Connector Layout (4) 898
Connector Contact Connection Table 899
T-Branch Box and T-Branch Adapter Table 939
Fuse Location Table 945
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 948
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 952
Failure Code Table 954
Troubleshooting by Failure Code (Display of Code) 973
Failure Code [6AZ0ZG] 973
Failure Code [879AKA] 975
Failure Code [879AKB] 976
Failure Code [879BKA] 977
Failure Code [879BKB] 979
Failure Code [879CKA] 981
Failure Code [879CKB] 982
Failure Code [879DKZ] 983
Failure Code [879EMC] 985
Failure Code [879FMC] 986
Failure Code [879GKX] 987
Failure Code [989L00] 989
Failure Code [989M00] 990
Failure Code [989N00] 991
Failure Code [A1U0N3] 992
Failure Code [A1U0N4] 994
Failure Code [A900FR] 996
Failure Code [A900N6] 997
Failure Code [A900NY] 998
Failure Code [AA10NX] 999
Failure Code [AB00KE] 1001
Failure Code [AQ10N3] 1004
Failure Code [AS00N3] 1006
Failure Code [AS00R2] 1008
Failure Code [AS00R3] 1009
Failure Code [AS00R4] 1010
Failure Code [AS00R5] 1011
Failure Code [AS00R6] 1012
Failure Code [AS00ZK] 1013
Failure Code [AS10KM] 1014
Failure Code [AS10NR] 1015
Failure Code [AS10NT] 1016
Failure Code [B@BAZG] 1017
Failure Code [B@BAZK] 1018
Failure Code [B@BCNS] 1020
Failure Code [B@BCQA] 1021
Failure Code [B@BCZK] 1023
Failure Code [B@HANS] 1025
Failure Code [CA115] 1026
Failure Code [CA122] 1027
Failure Code [CA123] 1029
Failure Code [CA131] 1031
Failure Code [CA132] 1033
Failure Code [CA144] 1035
Failure Code [CA145] 1037
Failure Code [CA153] 1039
Failure Code [CA154] 1042
Failure Code [CA187] 1044
Failure Code [CA221] 1046
Failure Code [CA222] 1048
Failure Code [CA227] 1050
Failure Code [CA234] 1051
Failure Code [CA238] 1052
Failure Code [CA239] 1054
Failure Code [CA249] 1056
Failure Code [CA256] 1058
Failure Code [CA271] 1060
Failure Code [CA272] 1062
Failure Code [CA322] 1064
Failure Code [CA323] 1066
Failure Code [CA324] 1068
Failure Code [CA325] 1070
Failure Code [CA331] 1072
Failure Code [CA332] 1074
Failure Code [CA343] 1076
Failure Code [CA351] 1077
Failure Code [CA352] 1078
Failure Code [CA356] 1081
Failure Code [CA357] 1083
Failure Code [CA386] 1085
Failure Code [CA428] 1086
Failure Code [CA429] 1088
Failure Code [CA435] 1090
Failure Code [CA441] 1092
Failure Code [CA442] 1094
Failure Code [CA449] 1095
Failure Code [CA451] 1096
Failure Code [CA452] 1098
Failure Code [CA488] 1100
Failure Code [CA515] 1101
Failure Code [CA516] 1103
Failure Code [CA553] 1105
Failure Code [CA555] 1106
Failure Code [CA556] 1107
Failure Code [CA559] 1108
Failure Code [CA595] 1111
Failure Code [CA687] 1112
Failure Code [CA689] 1114
Failure Code [CA691] 1117
Failure Code [CA692] 1119
Failure Code [CA697] 1121
Failure Code [CA698] 1122
Failure Code [CA731] 1123
Failure Code [CA778] 1125
Failure Code [CA1117] 1130
Failure Code [CA1664] 1131
Failure Code [CA1669] 1133
Failure Code [CA1673] 1134
Failure Code [CA1677] 1135
Failure Code [CA1678] 1136
Failure Code [CA1682] 1137
Failure Code [CA1683] 1139
Failure Code [CA1684] 1141
Failure Code [CA1686] 1143
Failure Code [CA1691] 1144
Failure Code [CA1694] 1147
Failure Code [CA1695] 1150
Failure Code [CA1696] 1151
Failure Code [CA1712] 1153
Failure Code [CA1713] 1156
Failure Code [CA1714] 1158
Failure Code [CA1715] 1159
Failure Code [CA1776] 1160
Failure Code [CA1777] 1163
Failure Code [CA1843] 1166
Failure Code [CA1844] 1168
Failure Code [CA1879] 1171
Failure Code [CA1881] 1173
Failure Code [CA1883] 1175
Failure Code [CA1885] 1178
Failure Code [CA1887] 1180
Failure Code [CA1921] 1182
Failure Code [CA1922] 1185
Failure Code [CA1942] 1190
Failure Code [CA1993] 1191
Failure Code [CA2185] 1194
Failure Code [CA2186] 1195
Failure Code [CA2249] 1197
Failure Code [CA2271] 1198
Failure Code [CA2272] 1201
Failure Code [CA2288] 1204
Failure Code [CA2311] 1205
Failure Code [CA2349] 1206
Failure Code [CA2353] 1209
Failure Code [CA2357] 1211
Failure Code [CA2381] 1212
Failure Code [CA2382] 1215
Failure Code [CA2383] 1218
Failure Code [CA2386] 1221
Failure Code [CA2387] 1223
Troubleshooting Flowchart 1227
Failure Code [CA2555] 1228
Failure Code [CA2556] 1231
Failure Code [CA2637] 1234
Failure Code [CA2639] 1236
Failure Code [CA2771] 1239
Failure Code [CA2777] 1245
Failure Code [CA2976] 1248
Failure Code [CA3133] 1250
Failure Code [CA3134] 1253
Failure Code [CA3135] 1255
Failure Code [CA3142] 1258
Failure Code [CA3143] 1259
Failure Code [CA3144] 1260
Failure Code [CA3146] 1262
Failure Code [CA3147] 1263
Failure Code [CA3148] 1264
Failure Code [CA3151] 1266
Failure Code [CA3165] 1272
Failure Code [CA3229] 1274
Failure Code [CA3231] 1276
Failure Code [CA3232] 1278
Failure Code [CA3235] 1282
Failure Code [CA3239] 1284
Failure Code [CA3241] 1287
Failure Code [CA3242] 1290
Failure Code [CA3251] 1293
Failure Code [CA3253] 1295
Failure Code [CA3254] 1298
Failure Code [CA3255] 1301
Failure Code [CA3256] 1305
Failure Code [CA3311] 1307
Failure Code [CA3312] 1309
Failure Code [CA3313] 1312
Failure Code [CA3314] 1313
Failure Code [CA3315] 1314
Failure Code [CA3316] 1316
Failure Code [CA3317] 1317
Failure Code [CA3318] 1318
Failure Code [CA3319] 1320
Failure Code [CA3321] 1321
Failure Code [CA3322] 1323
Failure Code [CA3419] 1325
Failure Code [CA3421] 1327
Failure Code [CA3497] 1329
Failure Code [CA3498] 1330
Failure Code [CA3543] 1331
Failure Code [CA3545] 1338
Failure Code [CA3547] 1340
Failure Code [CA3558] 1341
Failure Code [CA3559] 1343
Failure Code [CA3562] 1345
Failure Code [CA3563] 1347
Failure Code [CA3567] 1350
Failure Code [CA3568] 1353
Failure Code [CA3571] 1357
Failure Code [CA3572] 1359
Failure Code [CA3574] 1361
Failure Code [CA3575] 1363
Failure Code [CA3577] 1365
Failure Code [CA3578] 1367
Failure Code [CA3582] 1369
Failure Code [CA3583] 1375
Failure Code [CA3596] 1377
Failure Code [CA3649] 1379
Failure Code [CA3681] 1381
Failure Code [CA3682] 1386
Failure Code [CA3713] 1392
Failure Code [CA3717] 1395
Failure Code [CA3718] 1396
Failure Code [CA3725] 1397
Failure Code [CA3741] 1400
Failure Code [CA3748] 1401
Failure Code [CA3751] 1403
Failure Code [CA3755] 1405
Failure Code [CA3866] 1407
Failure Code [CA3867] 1411
Failure Code [CA3868] 1414
Failure Code [CA3899] 1418
Failure Code [CA3911] 1420
Failure Code [CA3912] 1424
Failure Code [CA3932] 1426
Failure Code [CA3933] 1428
Failure Code [CA3934] 1430
Failure Code [CA3935] 1433
Failure Code [CA3936] 1435
Failure Code [CA4151] 1437
Failure Code [CA4152] 1441
Failure Code [CA4155] 1445
Failure Code [CA4156] 1447
Failure Code [CA4157] 1450
Failure Code [CA4158] 1452
Failure Code [CA4159] 1453
Failure Code [CA4161] 1454
Failure Code [CA4162] 1457
Failure Code [CA4163] 1460
Failure Code [CA4164] 1461
Failure Code [CA4165] 1463
Failure Code [CA4166] 1465
Failure Code [CA4168] 1466
Failure Code [CA4169] 1469
Failure Code [CA4171] 1471
Failure Code [CA4249] 1474
Failure Code [CA4251] 1476
Failure Code [CA4259] 1478
Failure Code [CA4261] 1481
Failure Code [CA4277] 1484
Failure Code [CA4281] 1487
Failure Code [CA4459] 1490
Failure Code [CA4461] 1492
Failure Code [CA4658] 1495
Failure Code [CA4731] 1499
Failure Code [CA4732] 1500
Failure Code [CA4739] 1501
Failure Code [CA4768] 1502
Failure Code [CA4769] 1504
Failure Code [CA4842] 1507
Failure Code [CA4952] 1511
Failure Code [CA5115] 1513
Failure Code [CA5179] 1516
Failure Code [CA5181] 1518
Failure Code [CA5383] 1520
Failure Code [D110KB] 1522
Failure Code [D19JKZ] 1524
Failure Code [D811MC] 1527
Failure Code [D862KA] 1528
Failure Code [D8ALKA] 1530
Failure Code [D8ALKB] 1533
Failure Code [D8AQKR] 1535
Failure Code [D8G1KT] 1542
Failure Code [D8G6KT] 1543
Failure Code [DA20MC] 1544
Failure Code [DA22KK] 1545
Failure Code [DA25KP] 1548
Failure Code [DA26KP] 1551
Failure Code [DA29KQ] 1554
Failure Code [DA2LKA] 1556
Failure Code [DA2LKB] 1559
Failure Code [DA2QKR] 1561
Failure Code [DA2RKR] 1570
Failure Code [DAF0KM] 1571
Failure Code [DAF0MB] 1572
Failure Code [DAF0MC] 1573
Failure Code [DAF8KB] 1574
Failure Code [DAF9KQ] 1576
Failure Code [DAFGMC] 1577
Failure Code [DAFLKA] 1578
Failure Code [DAFLKB] 1581
Failure Code [DAFQKR] 1583
Failure Code [DAZ9KQ] 1591
Failure Code [DAZQKR] 1592
Failure Code [DB2QKR] 1599
Failure Code [DB2RKR] 1607
Failure Code [DBP0KM] 1612
Failure Code [DBP0KT] 1613
Failure Code [DBP5KB] 1614
Failure Code [DBP5KY] 1617
Failure Code [DBPQKR] 1620
Failure Code [DDNRKA] 1628
Failure Code [DDNRKY] 1630
Failure Code [DDNS00] 1632
Failure Code [DGH2KA] 1634
Failure Code [DGH2KB] 1636
Failure Code [DHA4KA] 1638
Failure Code [DHAAMA] 1640
Failure Code [DHACMA] 1642
Failure Code [DHPAMA] 1644
Failure Code [DHPBMA] 1647
Failure Code [DHS3MA] 1650
Failure Code [DHS4MA] 1653
Failure Code [DHS8MA] 1656
Failure Code [DHS9MA] 1659
Failure Code [DHSAMA] 1662
Failure Code [DHSBMA] 1665
Failure Code [DHSCMA] 1668
Failure Code [DHSDMA] 1671
Failure Code [DHSFMA] 1674
Failure Code [DHSGMA] 1677
Failure Code [DHSHMA] 1680
Failure Code [DHSJMA] 1683
Failure Code [DHX1MA] 1686
Failure Code [DHZAMA] 1688
Failure Code [DHZCL8] 1692
Failure Code [DKR0MA] 1693
Failure Code [DKR1MA] 1696
Failure Code [DKULKA] 1699
Failure Code [DKULKB] 1701
Failure Code [DKULKY] 1703
Failure Code [DLM5KA] 1705
Failure Code [DLM5MB] 1707
Failure Code [DR10KA] 1709
Failure Code [DR12KA] 1712
Failure Code [DR20KA] 1714
Failure Code [DR21KX] 1716
Failure Code [DR30KA] 1718
Failure Code [DR31KX] 1720
Failure Code [DR40KA] 1722
Failure Code [DUMBKA] 1724
Failure Code [DUMBKB] 1727
Failure Code [DV20KB] 1729
Failure Code [DW43KA] 1731
Failure Code [DW43KB] 1733
Failure Code [DW43KY] 1735
Failure Code [DW45KA] 1737
Failure Code [DW45KB] 1740
Failure Code [DW45KY] 1743
Failure Code [DW4CKY] 1745
Failure Code [DW91KA] 1747
Failure Code [DW91KB] 1749
Failure Code [DW91KY] 1751
Failure Code [DWA2KA] 1753
Failure Code [DWA2KB] 1755
Failure Code [DWA2KY] 1757
Failure Code [DWK0KA] 1759
Failure Code [DWK0KB] 1761
Failure Code [DWK0KY] 1763
Failure Code [DWK2KA] 1765
Failure Code [DWK2KB] 1767
Failure Code [DWK2KY] 1769
Failure Code [DWK8KA] 1771
Failure Code [DWK8KB] 1773
Failure Code [DWK8KY] 1775
Failure Code [DWN5KA] 1777
Failure Code [DWN5KB] 1779
Failure Code [DWN5KY] 1781
Failure Code [DWPUKA] 1783
Failure Code [DWPUKB] 1785
Failure Code [DWPUKY] 1787
Failure Code [DXA8KA] 1789
Failure Code [DXA8KB] 1791
Failure Code [DXA9KA] 1793
Failure Code [DXA9KB] 1795
Failure Code [DXE0KA] 1797
Failure Code [DXE0KB] 1799
Failure Code [DXE4KA] 1801
Failure Code [DXE4KB] 1803
Failure Code [DXE4KY] 1805
Failure Code [DXE5KA] 1807
Failure Code [DXE5KB] 1809
Failure Code [DXE6KA] 1811
Failure Code [DXE6KB] 1813
Failure Code [DXE7KA] 1815
Failure Code [DXE7KB] 1817
Failure Code [DXE7KY] 1819
Failure Code [DXE8KA] 1821
Failure Code [DXE8KB] 1823
Failure Code [DXE8KY] 1825
Failure Code [DXE9KA] 1827
Failure Code [DXE9KB] 1829
Failure Code [DXE9KY] 1831
Failure Code [DXEAKA] 1833
Failure Code [DXEAKB] 1835
Failure Code [DXEAKY] 1837
Failure Code [DXEKKA] 1839
Failure Code [DXEKKB] 1841
Failure Code [DXEKKY] 1843
Failure Code [DXELKA] 1845
Failure Code [DXELKB] 1847
Failure Code [DXELKY] 1849
Failure Code [DY20KA] 1851
Failure Code [DY20MA] 1853
Failure Code [DY2CKB] 1855
Failure Code [DY2DKB] 1858
Failure Code [DY2EKB] 1860
Failure Code [F311KA] 1862
Failure Code [F311KB] 1864
Failure Code [F312KA] 1866
Failure Code [F312KB] 1868
Failure Code [F313KA] 1870
Failure Code [F313KB] 1872
Failure Code [F314KA] 1875
Failure Code [F314KB] 1877
Failure Code [F315KB] 1879
Failure Code [F315KY] 1881
Failure Code [F316KB] 1883
Failure Code [F316KY] 1885
Failure Code [F318KB] 1887
Failure Code [F318KY] 1890
Failure Code [F31AKB] 1892
Failure Code [F31AKY] 1894
Failure Code [F31BKB] 1896
Failure Code [F31BKY] 1898
Failure Code [F31CKB] 1900
Failure Code [F31CKY] 1902
Failure Code [F31DKB] 1904
Failure Code [F31DKY] 1906
Failure Code [F31EKB] 1908
Failure Code [F31EKY] 1910
Troubleshooting of Electrical System (E-Mode) 1912
E-1 Engine Does Not Start (Engine Does Not Crank) 1912
E-2 Manual Preheating System Does Not Operate 1918
E-3 Automatic Preheating System Does Not Operate 1921
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1923
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1925
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1928
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1929
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1930
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1931
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1932
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1933
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1934
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1935
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1936
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1937
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1938
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1939
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1941
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1942
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1943
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1944
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1946
E-23 Some Areas of Machine Monitor Screen are Not Shown 1947
E-24 Function Switch Does Not Operate 1948
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1949
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1950
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1951
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1952
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1953
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1954
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1955
E-32 Alarm Buzzer Cannot be Canceled 1957
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1958
E-34 Service Mode Cannot be Selected 1959
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1960
E-36 All Work Equipment, Swing and Travel Do Not Lock 1963
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1965
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1968
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1970
E-40 One-Touch Power Maximizing Function is Not Cancelled 1973
E-41 Alarm Does Not Sound During Travel 1974
E-42 Alarm Does Not Stop When Machine Stops 1976
E-43 Horn Does Not Sound 1977
E-44 Horn Does Not Stop 1980
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1982
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1983
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1985
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1986
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1987
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1988
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1989
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1990
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1991
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1992
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1993
E-56 Service is Not Shown Correctly with Monitoring Function 1994
E-57 Attachment Hydraulic Circuit Cannot be Changed 1996
E-58 KOMTRAX System Does Not Operate Correctly 1997
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1998
Information Shown in Troubleshooting Table (H-Mode) 1998
System Chart of Hydraulic and Mechanical Systems 1999
Failure Mode and Cause Table 2001
H-1 All Work Equipment, Swing and Travel Do Not Work 2010
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2011
H-3 Fine Control Performance or Response is Unsatisfactory 2014
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2015
H-5 Engine Speed Drops Largely or Engine Stops 2016
H-6 Speed or Power of Boom is Low 2018
H-7 Arm Speed or Power is Low 2022
H-8 Bucket Speed or Power is Low 2027
H-9 Work Equipment Does Not Move in Single Operation 2030
H-10 Hydraulic Drift of Boom is Large 2031
H-11 Hydraulic Drift of Arm is Large 2033
H-12 Hydraulic Drift of Bucket is Large 2035
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2036
H-14 Time Lag of Work Equipment is Large 2037
H-15 One-Touch Power Maximizing Function Does Not Operate 2038
H-16 Attachment Circuit Cannot be Changed 2039
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2040
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2041
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2042
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 2043
H-21 Machine Does Not Travel Straight 2044
H-22 Machine is Not Steered Correctly or Steering Power is Low 2046
H-23 Travel Speed is Low 2049
H-24 One of Tracks Does Not Run 2051
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2052
H-26 Upper Structure Does Not Swing to Right and Left 2053
H-27 Upper Structure Swings Only to Right or Left 2054
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 2055
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2056
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2057
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2058
H-32 Shock is Large When Upper Structure Stops Swing Operation 2059
H-33 There is Large Unusual Noise When It Stops Swing Operation 2060
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2061
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2062
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2063
H-37 Unusual Noise is Heard from Around Fan 2064
Troubleshooting of Engine (S-Mode) 2065
Information Shown in Troubleshooting Table (S-Mode) 2065
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2066
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2067
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2068
S-4 Engine Startability is Unsatisfactory 2070
S-5 Engine Does Not Pick Up Smoothly 2072
S-6 Engine Stops During Operation 2074
S-7 Engine Runs Rough or is Not Stable 2076
S-8 Engine Lacks Power 2077
S-9 KDPF Becomes Clogged in a Short Time 2079
S-10 Engine Oil Consumption is Excessive 2081
S-11 Oil Becomes Dirty Quickly 2082
S-12 Fuel Consumption is Excessive 2083
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2084
S-14 Oil Pressure Drops 2085
S-15 Fuel Mixes Into Engine Oil 2087
S-16 Water Mixes Into Engine Oil (Milky) 2088
S-17 Coolant Temperature Increases Too High (Overheating) 2089
S-18 Unusual Noise is Heard 2090
S-19 Vibration is Excessive 2091
S-20 Air Cannot be Bled from Fuel Circuit 2092
S-21 Active Regeneration is Done Frequently 2093
S-22 Active Regeneration Continues Long 2095
S-23 White Smoke is Exhausted During Active Regeneration 2096
S-24 DEF Consumption is Excessive 2097
S-25 There is Unusual Smell (Irritating Odor) 2099
S-26 Foreign Materials Enter DEF (DEF Increases) 2100
50 Disassembly and Assembly 2101
Table of Contents 2102
Precautions Before Work 2107
Related Information on Disassembly and Assembly 2108
How to Read This Manual 2108
Coating Materials List 2109
Special Tool List 2114
Sketches of Special Tools 2127
Engine and Cooling System 2132
Remove and Install Supply Pump Assembly 2132
Remove Supply Pump Assembly 2132
Install Supply Pump Assembly 2135
Remove and Install Injector Assembly 2138
How to Remove Injector Assembly 2138
How to Install Injector Assembly 2143
Remove and Install Cylinder Head Assembly 2151
How to Remove Cylinder Head Assembly 2152
How to Install Cylinder Head Assembly 2161
Remove and Install EGR Valve Assembly 2177
Remove EGR Valve Assembly 2177
Install EGR Valve Assembly 2178
Remove and Install EGR Cooler Assembly 2180
How to Remove EGR Cooler Assembly 2180
How to Install EGR Cooler Assembly 2184
Remove and Install Starter Assembly 2189
Remove Starting Motor Assembly 2189
Install Starting Motor Assembly 2190
Remove and Install Alternator Belt 2193
Remove Alternator Belt 2193
Install Alternator Belt 2195
Remove and Install Radiator Assembly 2198
How to Remove Radiator Assembly 2198
How to Install Radiator Assembly 2200
Remove and Install Hydraulic Oil Cooler Assembly 2203
How to Remove Hydraulic Oil Cooler Assembly 2203
How to Install Hydraulic Oil Cooler Assembly 2206
Remove and Install Aftercooler Assembly 2209
Remove Aftercooler Assembly 2209
Install Aftercooler Assembly 2211
Remove and Install Fan Clutch Assembly 2213
How to Remove Fan Clutch Assembly 2213
How to Install Fan Clutch Assembly 2218
Remove and Install Fan 2222
Remove Fan 2222
Install Fan 2222
Remove and Install Engine and Main Pump Assembly 2223
Remove Engine and Main Pump Assembly 2223
Install Engine and Main Pump Assembly 2232
Remove and Install Engine Front Oil Seal 2244
How to Remove Engine Front Oil Seal 2244
How to Install Engine Front Oil Seal 2247
Remove and Install Engine Rear Oil Seal 2251
How to Remove Engine Rear Oil Seal 2251
How to Install Engine Rear Oil Seal 2252
Remove and Install Fuel Cooler Assembly 2255
Remove Fuel Cooler Assembly 2255
Install Fuel Cooler Assembly 2255
Remove and Install Engine Hood Assembly 2257
How to Remove Engine Hood Assembly 2257
How to Install Engine Hood Assembly 2259
Remove and Install Fuel Tank Assembly 2264
Remove Fuel Tank Assembly 2264
Install Fuel Tank Assembly 2268
Remove and Install DEF Tank Assembly 2274
How to Remove DEF Tank Assembly 2274
How to Install DEF Tank Assembly 2279
Remove and Install DEF Tank Sensor Flange Assembly 2285
How to Remove DEF Tank Sensor Flange Assembly 2285
How to Install DEF Tank Sensor Flange Assembly 2291
Remove and Install DEF Tank Sensor 2297
Remove DEF Tank Sensor 2297
Install DEF Tank Sensor 2297
Remove and Install DEF Tank Strainer 2304
Remove DEF Tank Strainer 2304
Install DEF Tank Strainer 2304
Remove and Install DEF Tank Filler Port Filter 2305
Remove DEF Tank Filler Port Filter 2305
Install DEF Tank Filler Port Filter 2307
Remove and Install KDPF Assembly 2310
How to Remove KDPF Assembly 2310
How to Install KDPF Assembly 2312
Disassemble and Assemble KDPF Assembly 2314
Disassemble KDPF Assembly 2315
Assemble KDPF Assembly 2318
Remove and Install SCR Assembly 2323
How to Remove SCR Assembly 2323
How to Install SCR Assembly 2325
Remove and Install KDPF and SCR Assembly 2327
How to Remove KDPF and SCR Assembly 2327
Install KDPF and SCR Assembly 2334
Remove and Install KDPF and SCR Assembly Bracket 2340
Remove KDPF and SCR Assembly Bracket 2340
Install KDPF and SCR Assembly Bracket 2347
Remove and Install Bellows Pipe Assembly 2354
How to Remove Bellows Pipe Assembly 2354
How to Install Bellows Pipe Assembly 2356
Remove and Install KCCV Assembly 2360
Remove KCCV Assembly 2360
Install KCCV Assembly 2362
Remove and Install DEF Mixing Tube 2367
Remove DEF Mixing Tube 2367
Install DEF Mixing Tube 2373
Remove and Install DEF Injector 2379
Remove DEF Injector 2379
Install DEF Injector 2382
Remove and Install DEF Pump 2385
Remove DEF Pump 2385
Install DEF Pump 2388
Remove and Install DEF Hose 2391
Remove DEF Hose 2391
Install DEF Hose 2399
Remove and Install Air Cleaner Assembly 2405
Remove Air Cleaner Assembly 2405
Install Air Cleaner Assembly 2406
Remove and Install Air Conditioner Compressor Assembly 2408
Remove Air Conditioner Compressor Assembly 2408
How to Install Air Conditioner Compressor Assembly 2410
Remove and Install Air Conditioner Condenser Assembly 2413
How to Remove Air Conditioner Condenser Assembly 2413
How to Install Air Conditioner Condenser Assembly 2414
Power Train 2415
Remove and Install Travel Motor and Final Drive Assembly 2415
Remove Travel Motor and Final Drive Assembly 2415
Install Travel Motor and Final Drive Assembly 2416
Disassemble and Assemble Final Drive Assembly 2418
Disassemble Final Drive Assembly 2418
Assemble Final Drive Assembly 2422
Remove and Install Swing Motor and Swing Machinery Assembly 2431
Remove Swing Motor and Swing Machinery Assembly 2431
Install Swing Motor and Swing Machinery Assembly 2433
Disassemble and Assemble Swing Machinery Assembly 2437
Disassemble Swing Machinery Assembly 2437
Assemble Swing Machinery Assembly 2441
Remove and Install Swing Circle Assembly 2448
Remove Swing Circle Assembly 2448
Install Swing Circle Assembly 2448
Undercarriage and Frame 2450
Separate and Connect Track Assembly 2450
Separate Track Assembly 2450
Install Track Assembly 2452
Remove and Install Sprocket 2455
Remove Sprocket 2455
Install Sprocket 2455
Remove and Install Idler and Idler Cushion Assembly 2457
Remove Idler and Idler Cushion Assembly 2457
Install Idler and Idler Cushion Assembly 2458
Disassemble and Assemble Idler Assembly 2459
Disassemble Idler Assembly 2459
Assemble Idler Assembly 2460
Disassemble and Assemble Idler Cushion Assembly 2464
Disassemble Idler Cushion Assembly 2465
Assemble Idler Cushion Assembly 2465
Disassemble and Assemble Track Roller Assembly 2467
Disassemble Track Roller Assembly 2468
Assemble Track Roller Assembly 2469
Disassemble and Assemble Carrier Roller Assembly 2471
Disassemble Carrier Roller Assembly 2471
Assemble Carrier Roller Assembly 2473
Remove and Install Revolving Frame Assembly 2475
Remove Revolving Frame Assembly 2475
Install Revolving Frame Assembly 2477
Remove and Install Counterweight Assembly 2480
Remove Counterweight Assembly 2480
Install Counterweight Assembly 2483
Hydraulic System 2487
Remove and Install Center Swivel Joint Assembly 2487
Remove Center Swivel Joint Assembly 2487
Install Center Swivel Joint Assembly 2489
Disassemble and Assemble Center Swivel Joint Assembly 2492
Disassemble Center Swivel Joint Assembly 2492
Assemble Center Swivel Joint Assembly 2493
Remove and Install Hydraulic Tank Assembly 2495
Remove Hydraulic Tank Assembly 2495
How to Install Hydraulic Tank Assembly 2498
Remove and Install Main Pump Assembly 2502
Remove Main Pump Assembly 2502
Install Main Pump Assembly 2505
Remove and Install Control Valve Assembly 2509
How to Remove Control Valve Assembly 2509
How to Install Control Valve Assembly 2516
Disassemble and Assemble Control Valve Assembly 2524
Replace Pressure Compensation Valve Seal Ring 2524
Assemble Control Valve Assembly 2525
Disassemble and Assemble Work Equipment PPC Valve Assembly 2529
Disassemble Work Equipment PPC Valve Assembly 2529
How to Assemble Work Equipment PPC Valve Assembly 2529
Disassemble and Assemble Travel PPC Valve Assembly 2531
Disassemble Travel PPC Valve Assembly 2531
How to Assemble Travel PPC Valve Assembly 2532
Work Equipment 2534
Remove and Install Work Equipment Assembly 2534
Remove Work Equipment Assembly 2534
Install Work Equipment Assembly 2538
Remove and Install Boom Anti-drop Valve Assembly 2543
Remove Boom Anti-drop Valve Assembly 2543
Install Boom Anti-drop Valve Assembly 2545
Remove and Install Arm Anti-Drop Valve Assembly 2546
Remove Arm Anti-Drop Valve Assembly 2546
Install Arm Anti-Drop Valve Assembly 2548
Disassemble and Assemble Anti-Drop Valve Assembly 2549
Disassemble Anti-Drop Valve Assembly 2549
Assemble Anti-Drop Valve Assembly 2549
Disassemble and Assemble Work Equipment Cylinder Assembly 2550
How to Disassemble Work Equipment Cylinder Assembly 2550
How to Assemble Work Equipment Cylinder Assembly 2553
CAB Related Parts 2559
Remove and Install Operator Cab Assembly 2559
How to Remove Operator Cab Assembly 2559
Install Operator CAB Assembly 2567
Remove and Install Operator Cab Glass (Adhered Glass) 2574
Remove Operator CAB Glass (Adhered Glass) 2576
Install Operator CAB Glass (Adhered Glass) 2576
Remove and Install Front Window Assembly 2586
Remove Front Window Assembly 2586
Install Front Window Assembly 2589
Remove and Install Floor Frame Assembly 2595
How to Remove Floor Frame Assembly 2595
How to Install Floor Frame Assembly 2602
Remove and Install Air Conditioner Unit Assembly 2609
Remove Air Conditioner Unit Assembly 2609
Install Air Conditioner Unit Assembly 2615
Remove and Install Operator Seat 2622
Remove Operator’s Seat 2622
Install Operator’s Seat 2624
How to Remove and Install Seat Belt 2627
How to Remove Seat Belt 2627
How to Install Seatbelt 2628
Remove and Install Work Equipment Control Lever Assembly 2629
How to Remove Work Equipment Control Lever Assembly 2629
How to Install Work Equipment Control Lever Assembly 2635
Remove and Install Front Wiper Assembly 2644
Remove Front Wiper Assembly 2644
Install Front Wiper Assembly 2649
Electrical System 2658
Remove and Install Engine Controller Assembly 2658
Remove Engine Controller Assembly 2658
Install Engine Controller Assembly 2659
Remove and Install Pump Controller Assembly 2661
Remove Pump Controller Assembly 2661
Install Pump Controller Assembly 2665
Remove and Install KomVision Controller Assembly 2670
Remove KomVision Controller Assembly 2670
Install KomVision Controller Assembly 2671
Remove and Install Machine Monitor Assembly 2672
Remove Machine Monitor Assembly 2672
Install Machine Monitor Assembly 2675
Remove and Install Pump Swash Plate Sensor 2679
Remove Pump Swash Plate Sensor 2679
Install Pump Swash Plate Sensor 2680
Remove and Install Mass Air Flow and Temperature Sensor 2681
How to Remove Mass Air Flow and Temperature Sensor 2681
How to Install Mass Air Flow and Temperature Sensor 2681
Remove and Install KCCV Crankcase Pressure Sensor 2683
How to Remove KCCV Crankcase Pressure Sensor 2683
How to Install KCCV Crankcase Pressure Sensor 2684
Remove and Install SCR Temperature Sensor 2685
Remove SCR Temperature Sensor 2685
Install SCR Temperature Sensor 2687
Remove and Install KomVision Camera 2690
Remove KomVision Camera 2690
Install KomVision Camera 2691
Remove and Install Gateway Function Controller Assembly 2693
Remove Gateway Function Controller Assembly 2693
How to Install Gateway Function Controller Assembly 2698
Remove and Install Communication Terminal Wiring Harness 2703
Remove Communication Terminal Wiring Harness 2703
Install Communication Terminal Wiring Harness 2711
Remove and Install Communication Terminal 2720
Remove Communication Terminal 2720
Install Communication Terminal 2722
60 Maintenance Standard 2725
Table of Contents 2726
Engine and Cooling System 2727
Maintenance Standard for Engine Mount 2727
Maintenance Standard for Cooling System 2728
Power Train 2730
Maintenance Standard for Swing Circle 2730
Maintenance Standard for Swing Machinery 2731
Maintenance Standard for Final Drive 2733
Maintenance Standard for Sprocket 2735
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2736
Undercarriage and Frame 2737
Maintenance Standard for Track Frame and Idler Cushion 2737
Maintenance Standard for Idler 2739
Maintenance Standard for Track Roller 2741
Maintenance Standard for Carrier Roller 2742
Maintenance Standard for Track Shoes 2743
Maintenance Standard for Triple Shoes 2746
Maintenance Standard for Swamp Shoes 2747
Maintenance Standard for Road Liner 2748
Hydraulic System 2749
Maintenance Standard for Hydraulic Tank 2749
Maintenance Standard for Main Pump 2750
Maintenance Standard for LS-EPC Valve 2751
Maintenance Standard for PC-EPC Valve 2752
Maintenance Standard for Swing Motor 2753
Maintenance Standard for Travel Motor 2756
Maintenance Standard for Control Valve 2759
Maintenance Standard for Boom Anti-Drop Valve 2769
Maintenance Standard for Arm Anti-Drop Valve 2771
Maintenance Standard for Work Equipment and Swing PPC Valve 2773
Maintenance Standard for Travel PPC Valve 2776
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2779
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2780
Maintenance Standard for 2nd-Line Attachment PPC Valve 2782
Maintenance Standard for Solenoid Valve 2784
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2785
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2786
Maintenance Standard for Center Swivel Joint 2787
Work Equipment 2788
Maintenance Standard for Work Equipment Linkage 2788
Dimensions of Arm 2793
Dimensions of Bucket 2795
Maintenance Standard for Boom Cylinder (Large Diameter Piston) 2797
Maintenance Standard for Arm Cylinder 2798
Maintenance Standard for Bucket Cylinder 2799
80 Appendix 2801
Table of Contents 2802
Precautions Before Work 2804
Air Conditioner System 2805
Precautions for Refrigerant 2805
Air Conditioner Component 2806
Specifications of Air Conditioner 2808
Structure and Function of Refrigeration Cycle 2809
Outline of Refrigeration Cycle 2810
Component Parts of Air Conditioner System 2812
Air Conditioner Unit 2812
Configuration Diagram of Air Conditioner Unit 2812
Function of Air Conditioner Unit 2814
Component Parts of Air Conditioner Unit 2816
Function of Evaporator as Air Conditioner Unit Component 2817
Function of Heater Core as Air Conditioner Unit Component 2817
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2817
Function of Servo Motor as Air Conditioner Unit Component 2817
Structure of Expansion Valve as Air Conditioner Unit Component 2818
Function of Expansion Valve as Air Conditioner Unit Component 2818
Operate Expansion Valve as Air Conditioner Unit Component 2818
Function of Dual Pressure Switch 2819
Air Conditioner Controller 2820
Structure of Air Conditioner Controller 2820
Compressor 2821
Structure of Compressor 2821
Specifications of Compressor 2821
Function of Compressor 2821
Condenser 2822
Structure of Condenser 2822
Specifications of Condenser 2822
Function of Condenser 2822
Air Conditioner Related Sensors 2824
Structure of Sunlight Sensor 2824
Function of Sunlight Sensor 2824
Structure of Outside Temperature Sensor 2824
Function of Outside Air Temperature Sensor 2824
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2826
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2828
System Diagram of Air Conditioner 2830
Input and Output Signals of Air Conditioner Controller 2831
Function of Air Conditioner Controller 2832
Locations of Air Conditioner Parts and Layout of Connectors 2833
Examine Air Leakage (Duct) 2837
How to Examine Air Leakage (Duct) 2837
Examine Air Conditioner with Self-Diagnosis Function 2839
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2840
Examine Vent (Mode) Changeover 2841
How to Examine Vent (Mode) Changeover 2841
Examine Fresh/Recirc Air Changeover 2843
How to Examine Fresh/Recirc Air Changeover 2843
Examine Sunlight Sensor 2844
How to Examine Sunlight Sensor 2844
Examine Refrigerant (Dual) Pressure Switch 2845
How to Examine Refrigerant (Dual) Pressure Switch 2845
Examine Relay 2846
How to Examine Relay 2846
Air Conditioner Troubleshooting Chart 1 2847
Air Conditioner Troubleshooting Chart 2 2848
Information Shown in Troubleshooting Table 2851
Failure Code [879AKA] 2852
Failure Code [879AKB] 2853
Failure Code [879BKA] 2854
Failure Code [879BKB] 2856
Failure Code [879CKA] 2858
Failure Code [879CKB] 2859
Failure Code [879DKZ] 2860
Failure Code [879EMC] 2862
Failure Code [879FMC] 2863
Failure Code [879GKX] 2864
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2866
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2868
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2871
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2873
Troubleshooting by Gauge Pressure 2875
Connect Service Tool 2878
How to Connect Service Tool 2878
Precautions for Disconnection and Connection of Air Conditioner Piping 2880
Handle Compressor Oil 2882
Replace Desiccant 2884
90 Circuit Diagrams 2887
Table of Contents 2888
Hydraulic Circuit Diagram 2889
Symbols Used in Hydraulic Circuit Diagram 2889
Hydraulic Circuit Diagram (1/2) 2893
Hydraulic Circuit Diagram (2/2) 2895
Electrical Circuit Diagram 2897
Symbols Used in Electric Circuit Diagram 2897
Electrical Circuit Diagram (1/10) 2901
Electrical Circuit Diagram (2/10) 2903
Electrical Circuit Diagram (3/10) 2905
Electrical Circuit Diagram (4/10) 2907
Electrical Circuit Diagram (5/10) 2909
Electrical Circuit Diagram (6/10) 2911
Electrical Circuit Diagram (7/10) 2913
Electrical Circuit Diagram (8/10) 2915
Electrical Circuit Diagram (9/10) 2917
Electrical Circuit Diagram (10/10) 2919
Index 2921

S.V  21/12/24