Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06807-09 PDF

Description

Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06807-09 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06807-09 – PDF DOWNLOAD 

Language : English
Pages : 2946
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06807-09 – PDF DOWNLOAD 

SERIAL NUMBERS 95321 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 PC240LC-11 Hydraulic Excavator Shop Manual SEN06807-09 – PDF DOWNLOAD 

SERIAL NUMBERS 95321 and up

00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC240LC-11 93
Working Range Drawings 95
Working Range: PC240LC-11 95
Specifications 96
Specifications: PC240LC-11 96
Weight Table 99
Weight Table: PC240LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 108
Urea SCR System Diagram 113
Function of Urea SCR System 114
Function of DEF System 114
Inducement Strategy 116
Component Parts of Urea SCR System 124
DEF Mixing Tube 124
SCR Assembly 124
DEF Tank 127
DEF Pump 129
DEF Injector 130
DEF Hose 131
DEF Tank Heating Valve 132
Boot-up System 133
Layout Drawing of Boot-up System 133
System Operating Lamp System 135
System Diagram of System Operating Lamp System 135
Function of Operation Lamp System 135
Battery Isolator 137
Function of Battery Isolator 137
Engine System 138
Layout Drawing of Engine System 138
Specifications of Engine System 139
Function of Engine System 139
Engine Control System 140
System Diagram of Engine Control 140
Function of Engine Control System 141
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
Automatic Idle Stop System 153
System Diagram of Automatic Idle Stop System 153
Function of Automatic Idle Stop System 153
Component Parts of Engine System 156
VGT 156
EGR System 160
EGR Valve 162
EGR Cooler 164
KCCV System 165
KCCV Ventilator 167
KDPF 169
Cooling System 174
Layout Drawing of Cooling System 174
Specifications of Cooling System 175
Control System 176
Layout Drawing of Control System 176
Machine Monitor System 179
System Diagram of Machine Monitor System 179
Function of Machine Monitor System 179
KomVision System 181
Layout Drawing of KomVision System 181
System Diagram of KomVision System 183
Function of KomVision System 183
KOMTRAX System 185
System Diagram of KOMTRAX System 185
Function of KOMTRAX System 185
PPC Levers 186
LH PPC Lever 186
RH PPC Lever 187
Automatic Grease System 188
Outline of AUTO Grease System 188
Component Parts of Control System 200
Machine Monitor 200
KomVision Controller 213
KomVision Camera 217
Gateway Function Controller 218
Communication Terminal 221
Pump Controller 223
Resistor for PC-EPC Valve 227
CAN Terminating Resistor 227
PPC Oil Pressure Switch 228
Engine Controller 229
Fuel Control Dial 235
Hydraulic System 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
Pilot Oil Filter 301
Control Valve 301
Work Equipment System 365
Layout Drawing of Work Equipment System 365
Structure of Valve Control 370
One-Touch Power Maximizing System 372
System Diagram of One-Touch Power Maximizing System 372
Function of One-Touch Power Maximizing System 373
PPC Lock System 374
System Diagram of PPC Lock 374
Function of PPC Lock System 374
Work Equipment and Travel Automatic Lock System 375
System Diagram of Lock Lever Automatic Lock System 375
Function of Work Equipment and Travel Automatic Lock System 375
Operation of Lock Lever Automatic Lock System 376
Attachment Oil Flow Adjuster System 377
Attachment Oil Flow Adjuster System Diagram 377
Function of Attachment Oil Flow Adjuster System 378
Tool Control System 379
Tool Control System Diagram 379
Component Parts of Work Equipment System 381
Work Equipment and Swing PPC Valve 381
1st-Line Attachment PPC Valve (with EPC Valve) 387
2nd-Line Attachment PPC Valve 393
Solenoid Valve 395
Boom Anti-drop Valve 398
Arm Anti-Drop Valve 402
Attachment Circuit Selector Valve (For High Pressure) 406
Attachment Circuit Selector Valve (For Low Pressure) 408
Pilot Circuit Accumulator 411
Attachment Circuit Accumulator 412
Swing System 413
Layout Drawing of Swing System 413
Swing Control System Diagram 417
Function of Swing Control System 417
Component Parts of Swing System 421
Swing Motor 421
Swing Machinery 432
Swing Circle 433
Travel System 435
Layout Drawing of Travel System 435
System Diagram of Travel Control System 439
Function of Travel Control System 439
Component Parts of Travel System 441
Travel Motor 441
Final Drive 453
Travel PPC Valve 455
Center Swivel Joint 460
Undercarriage and Frame 462
Layout Drawing of Undercarriage 462
Specifications of Undercarriage 463
Work Equipment 464
Structure of Work Equipment 464
Function of Work Equipment 465
Work Equipment Clearance Adjustment Shim 466
Function of Work Equipment Clearance Adjustment Shim 466
Bucket Clearance Adjustment Shim 467
Function of Bucket Clearance Adjustment Shim 467
CAB Related Parts 468
ROPS CAB 468
Structure of ROPS CAB 468
Function of ROPS CAB 468
CAB Mount 469
Structure of CAB Mount 469
Function of CAB Mount 469
CAB Tipping Stopper 470
Structure of CAB Tipping Stopper 470
Function of CAB Tipping Stopper 470
20 Standard Value Table 471
Table of Contents 472
Standard Value Table for Engine 473
Standard Value Table for Engine: PC240LC-11 473
Standard Value Table for Machine 477
Standard Value Table for Machine: PC240LC-11 477
Machine Posture and Procedures to Measure Performance 490
Standard Value Table for Electricity 494
Standard Value Table for Electricity 494
30 Testing and Adjusting 505
Table of Contents 506
Precautions Before Work 509
Related Information on Testing and Adjusting 510
Tools for Testing and Adjusting 510
Sketch of Tools for Testing and Adjusting 517
Engine and Cooling System 519
Examine Engine Speed 519
How to Examine Engine Speed 519
Examine Boost Pressure 522
How to Examine Boost Pressure on Machine Monitor 522
How to Examine Boost Pressure by Testing Tool 523
Examine Exhaust Gas Color 524
How to Examine Exhaust Gas Color with the Handy Smoke Checker 524
How to Examine Exhaust Gas Color with Smoke Meter 525
Examine Mass Air Flow and Temperature Sensor 527
How to Examine Mass Air Flow and Temperature Sensor 527
Examine and Adjust Valve Clearance 529
How to Examine Valve Clearance 529
How to Adjust Valve Clearance 530
Examine Compression Pressure 532
How to Examine Compression Pressure 532
Examine Blowby Pressure 537
How to Examine Blowby Pressure 537
Examine Engine Oil Pressure 539
How to Examine Engine Oil Pressure 539
Examine EGR Valve and VGT Oil Pressure 540
How to Examine EGR Valve and VGT Oil Pressure 540
Examine Fuel Pressure 542
How to Examine Fuel Pressure 543
Examine Fuel Discharge, Return and Leakage 548
How to Examine Fuel Discharge, Return, and Leakage 549
Bleed Air from Fuel System 555
How to Bleed Air from Fuel System 555
Examine Fuel Circuit for Leakage 556
How to Examine Fuel System for Leakage 556
Handle Cylinder Cut-out Mode Operation 558
Handle No-Injection Cranking Operation 559
Examine and Adjust Air Conditioner Compressor Belt Tension 560
How to Examine Air Conditioner Compressor Belt 560
How to Adjust Air Conditioner Compressor Belt 560
Examine Fan Belt and Alternator Belt 562
How to Examine Fan Belt and Alternator Belt 562
Examine Automatic Tensioner 563
How to Examine Automatic Tensioner 563
How to Replace Fan Belt 564
Write Correction for Ash in Soot Accumulation to Engine Controller 565
How to Write Correction for Ash in Soot Accumulation to Engine Controller 565
Examine SCR Related Functions 566
Examine DEF Pump Raised Pressure 569
Examine Injection Volume from DEF Injector 572
Examine DEF Line Heater Relay 1 575
Examine DEF Line Heater Relay 2 578
Examine DEF Pump Heater Relay 581
Examine DEF Tank Heater Valve 584
Examine SCR Denitration Efficiency 587
Clean DEF Tank 591
How to Clean DEF Tank 591
Clean DEF Pump 595
How to Clean DEF Pump 595
Bleed Air from Coolant Circuit of DEF Tank 602
How to Bleed Air from Coolant Circuit of DEF Tank 602
Power Train 604
Examine Swing Circle Bearing Clearance 604
How to Examine Swing Circle Bearing Clearance 604
Undercarriage and Frame 605
Examine and Adjust Track Tension 605
How to Examine Track Tension 605
How to Adjust Track Tension 605
Hydraulic System 607
Release Remained Pressure in Hydraulic Circuit 607
How to Release Remained Pressure in Hydraulic System 607
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 613
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 614
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 620
Examine Oil Pressure of Control Circuit 623
How to Examine Oil Pressure in Control Circuit 623
Examine and adjust oil pressure in pump PC control circuit 625
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 625
Examine PC-EPC Valve Outlet Pressure 626
How to Adjust Oil Pressure in Pump PC Control Circuit 627
Examine and Adjust Oil Pressure in Pump LS Control Circuit 629
How to Examine LS Differential Pressure with Machine Monitor 629
How to Examine LS Differential Pressure by Testing Tool 630
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 633
How to Examine LS-EPC Valve Outlet Pressure 634
How to Adjust LS Valve 635
Examine Outlet Pressure of Solenoid Valve 636
How to Examine Outlet Pressure of Solenoid Valve 636
Operating Condition of Solenoid Valve 637
Examine PPC Valve Outlet Pressure 640
How to Examine Outlet Pressure in PPC Valve 640
Adjust Play of Work Equipment and Swing PPC Valves 642
How to Adjust Play of Work Equipment and Swing PPC Valves 642
Measure and Adjust Quick Coupler Control Valve Output Pressure 643
Examine Pump Swash Plate Sensor 645
How to Examine pump swash plate sensor 645
Examine Parts Which Cause Hydraulic Drift of Work Equipment 646
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 646
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 646
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 647
Examine Oil Leakage 648
How to Examine Oil Leakage from Boom Cylinder 648
How to Examine Oil Leakage from Arm Cylinder 648
How to Examine Oil Leakage from Bucket Cylinder 649
How to Examine Oil Leakage from Swing Motor 650
How to Examine Oil Leakage from Travel Motor 650
Bleed Air from Hydraulic System 651
How to Bleed Air from Hydraulic System 653
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 655
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 655
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 659
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 659
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 663
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 663
CAB Related Parts 670
Examine CAB Tipping Stopper 670
How to Examine Cab Tipping Stopper 670
How to Adjust Mirrors 671
Procedure to Adjust Machine Left Front Mirror (A) 671
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 672
Procedure to Adjust Machine Right Front Mirror (B) 673
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 674
Procedure to Adjust Machine Right Side Mirror (C) 675
Electrical System 677
Set and Operate Machine Monitor 677
Operator Mode 680
Function to Show Technician Identification Status Screen 681
Function to Show Operator Identification Input Screen 681
Examine Function by LCD (Liquid Crystal Display) 682
Examine Function of Service Meter 682
Usage Limitation and Maintenance Password Change Function 682
Service Mode 685
How to Operate Service Mode 685
How to See Pre-defined Monitoring Information 687
How to Examine Self-Define Monitor Information 694
Abnormality Record Menu 705
How to See Maintenance Record 709
Maintenance Mode Setting 710
How to Set Phone Number Entry 714
Default Menu 715
Diagnostic Tests Menu 727
Adjustment Menu 736
No-Injection Cranking Operation 757
KOMTRAX Settings Menu 758
How to Show Service Message 761
How to Start Up KOMTRAX System 763
Adjust Rearview Camera Angle 768
How to Adjust Rearview Camera Angle 768
Adjust KomVision Camera Angle 771
How to Adjust KomVision Camera Angle 772
Adjust KomVision Related Function 776
Setting of KomVision (Main Setting) 776
Setting of KomVision (Camera Setting) 778
Setting of KomVision (Camera Calibration) 780
KomVision screen – Check 12 m visibility 793
Set Region of Bluetooth(R) Compatible Radio 796
How to Set Region of Bluetooth(R) Compatible Radio 796
Handle Voltage Circuit of Engine Controller 798
Handle Battery Isolator Switch 799
Examine Diodes 800
How to Examine Diodes by Digital Tester 800
How to Examine Diodes by Analog Tester 800
Pm Clinic 801
Pm Clinic Service 801
Pm Clinic Check Sheet 805
40 Troubleshooting 817
Table of Contents 818
Precautions Before Work 829
Related Information to Troubleshooting 830
General Troubleshooting Points 830
Troubleshooting Points for Urea SCR System 831
Sequence of Events in Troubleshooting 845
Checks Before Troubleshooting 847
Inspection Procedure Before Troubleshooting 849
Walk-Around Check 849
Test in Accordance with Testing Procedure 851
Examine Fuel Level and Type 851
Examine for Impure Ingredient in Fuel 851
Examine Fuel Prefilter 852
Examine Water Separator, Drain Water and Sediment 852
How to Replace Fuel Prefilter Cartridge 853
Examine Fuel Main Filter 854
Examine Engine Oil Level (Oil Quantity in Oil Pan) 856
Examine Coolant Level (Reservoir Tank) 857
Examine Air Cleaner Clogging 857
Clean Outer Element 858
Replace Element 860
Examine Hydraulic Oil Level 861
Examine Hydraulic Oil Strainer 862
Examine Hydraulic Oil Filter 863
Examine Oil Level in Swing Machinery Case 864
Examine Oil Level in Damper Case 865
Examine Oil Level in Final Drive Case 865
Bleed Air from Fuel System 866
Bleed Air from Hydraulic System 866
How to Examine Electric Equipment 866
Automatic Grease System 874
Find Malfunctions 874
Malfunction Finding Procedures 876
Preparation for Troubleshooting of Electrical System 878
Procedure for Troubleshooting 891
Symptom and Troubleshooting Numbers 894
Information Shown in Troubleshooting Table 898
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 900
Connector List and Layout 903
Connector Contact Connection Table 916
T-Branch Box and T-Branch Adapter Table 956
Fuse Location Table 962
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 965
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 969
Failure Code Table 971
Troubleshooting by Failure Code (Display of Code) 990
Failure Code [6AZ0ZG] 990
Failure Code [879AKA] 992
Failure Code [879AKB] 993
Failure Code [879BKA] 994
Failure Code [879BKB] 996
Failure Code [879CKA] 998
Failure Code [879CKB] 999
Failure Code [879DKZ] 1000
Failure Code [879EMC] 1002
Failure Code [879FMC] 1003
Failure Code [879GKX] 1004
Failure Code [989L00] 1006
Failure Code [989M00] 1007
Failure Code [989N00] 1008
Failure Code [A1U0N3] 1009
Failure Code [A1U0N4] 1011
Failure Code [A900FR] 1013
Failure Code [A900N6] 1014
Failure Code [A900NY] 1015
Failure Code [AA10NX] 1016
Failure Code [AB00KE] 1018
Failure Code [AQ10N3] 1021
Failure Code [AS00N3] 1023
Failure Code [AS00R2] 1025
Failure Code [AS00R3] 1026
Failure Code [AS00R4] 1027
Failure Code [AS00R5] 1028
Failure Code [AS00R6] 1029
Failure Code [AS00ZK] 1030
Failure Code [AS10KM] 1031
Failure Code [AS10NR] 1032
Failure Code [AS10NT] 1033
Failure Code [B@BAZG] 1034
Failure Code [B@BAZK] 1035
Failure Code [B@BCNS] 1037
Failure Code [B@BCQA] 1038
Failure Code [B@BCZK] 1040
Failure Code [B@HANS] 1042
Failure Code [CA115] 1043
Failure Code [CA122] 1044
Failure Code [CA123] 1046
Failure Code [CA131] 1048
Failure Code [CA132] 1050
Failure Code [CA144] 1052
Failure Code [CA145] 1054
Failure Code [CA153] 1056
Failure Code [CA154] 1059
Failure Code [CA187] 1061
Failure Code [CA221] 1063
Failure Code [CA222] 1065
Failure Code [CA227] 1067
Failure Code [CA234] 1068
Failure Code [CA238] 1069
Failure Code [CA239] 1071
Failure Code [CA249] 1073
Failure Code [CA256] 1075
Failure Code [CA271] 1077
Failure Code [CA272] 1079
Failure Code [CA322] 1081
Failure Code [CA323] 1083
Failure Code [CA324] 1085
Failure Code [CA325] 1087
Failure Code [CA331] 1089
Failure Code [CA332] 1091
Failure Code [CA343] 1093
Failure Code [CA351] 1094
Failure Code [CA352] 1095
Failure Code [CA356] 1098
Failure Code [CA357] 1100
Failure Code [CA386] 1102
Failure Code [CA428] 1103
Failure Code [CA429] 1105
Failure Code [CA435] 1107
Failure Code [CA441] 1109
Failure Code [CA442] 1112
Failure Code [CA449] 1113
Failure Code [CA451] 1114
Failure Code [CA452] 1116
Failure Code [CA488] 1118
Failure Code [CA515] 1119
Failure Code [CA516] 1121
Failure Code [CA553] 1123
Failure Code [CA555] 1124
Failure Code [CA556] 1125
Failure Code [CA559] 1126
Failure Code [CA595] 1129
Failure Code [CA687] 1130
Failure Code [CA689] 1132
Failure Code [CA691] 1135
Failure Code [CA692] 1137
Failure Code [CA697] 1139
Failure Code [CA698] 1140
Failure Code [CA731] 1141
Failure Code [CA778] 1143
Failure Code [CA1117] 1148
Failure Code [CA1664] 1149
Failure Code [CA1669] 1151
Failure Code [CA1673] 1152
Failure Code [CA1677] 1153
Failure Code [CA1678] 1154
Failure Code [CA1682] 1155
Failure Code [CA1683] 1157
Failure Code [CA1684] 1159
Failure Code [CA1686] 1161
Failure Code [CA1691] 1162
Failure Code [CA1694] 1165
Failure Code [CA1695] 1168
Failure Code [CA1696] 1169
Failure Code [CA1712] 1171
Failure Code [CA1713] 1174
Failure Code [CA1714] 1176
Failure Code [CA1715] 1177
Failure Code [CA1776] 1178
Failure Code [CA1777] 1181
Failure Code [CA1843] 1184
Failure Code [CA1844] 1186
Failure Code [CA1879] 1189
Failure Code [CA1881] 1191
Failure Code [CA1883] 1193
Failure Code [CA1885] 1196
Failure Code [CA1887] 1198
Failure Code [CA1921] 1200
Failure Code [CA1922] 1203
Failure Code [CA1942] 1208
Failure Code [CA1993] 1209
Failure Code [CA2185] 1212
Failure Code [CA2186] 1213
Failure Code [CA2249] 1215
Failure Code [CA2271] 1216
Failure Code [CA2272] 1219
Failure Code [CA2288] 1222
Failure Code [CA2311] 1223
Failure Code [CA2349] 1224
Failure Code [CA2353] 1227
Failure Code [CA2357] 1229
Failure Code [CA2381] 1230
Failure Code [CA2382] 1233
Failure Code [CA2383] 1236
Failure Code [CA2386] 1239
Failure Code [CA2387] 1241
Troubleshooting Flowchart 1245
Failure Code [CA2555] 1246
Failure Code [CA2556] 1249
Failure Code [CA2637] 1252
Failure Code [CA2639] 1254
Failure Code [CA2771] 1257
Failure Code [CA2777] 1263
Failure Code [CA2976] 1266
Failure Code [CA3133] 1268
Failure Code [CA3134] 1271
Failure Code [CA3135] 1273
Failure Code [CA3142] 1276
Failure Code [CA3143] 1277
Failure Code [CA3144] 1278
Failure Code [CA3146] 1280
Failure Code [CA3147] 1281
Failure Code [CA3148] 1282
Failure Code [CA3151] 1284
Failure Code [CA3165] 1290
Failure Code [CA3229] 1292
Failure Code [CA3231] 1294
Failure Code [CA3232] 1296
Failure Code [CA3235] 1300
Failure Code [CA3239] 1302
Failure Code [CA3241] 1305
Failure Code [CA3242] 1308
Failure Code [CA3251] 1311
Failure Code [CA3253] 1313
Failure Code [CA3254] 1316
Failure Code [CA3255] 1319
Failure Code [CA3256] 1323
Failure Code [CA3311] 1325
Failure Code [CA3312] 1327
Failure Code [CA3313] 1330
Failure Code [CA3314] 1331
Failure Code [CA3315] 1332
Failure Code [CA3316] 1334
Failure Code [CA3317] 1335
Failure Code [CA3318] 1336
Failure Code [CA3319] 1338
Failure Code [CA3321] 1339
Failure Code [CA3322] 1341
Failure Code [CA3419] 1343
Failure Code [CA3421] 1345
Failure Code [CA3497] 1347
Failure Code [CA3498] 1348
Failure Code [CA3543] 1349
Failure Code [CA3545] 1356
Failure Code [CA3547] 1358
Failure Code [CA3558] 1359
Failure Code [CA3559] 1361
Failure Code [CA3562] 1363
Failure Code [CA3563] 1365
Failure Code [CA3567] 1368
Failure Code [CA3568] 1371
Failure Code [CA3571] 1375
Failure Code [CA3572] 1377
Failure Code [CA3574] 1379
Failure Code [CA3575] 1381
Failure Code [CA3577] 1383
Failure Code [CA3578] 1385
Failure Code [CA3582] 1387
Failure Code [CA3583] 1393
Failure Code [CA3596] 1395
Failure Code [CA3649] 1397
Failure Code [CA3681] 1399
Failure Code [CA3682] 1404
Failure Code [CA3713] 1409
Failure Code [CA3717] 1412
Failure Code [CA3718] 1413
Failure Code [CA3725] 1414
Failure Code [CA3741] 1417
Failure Code [CA3748] 1418
Failure Code [CA3751] 1420
Failure Code [CA3755] 1422
Failure Code [CA3866] 1424
Failure Code [CA3867] 1428
Failure Code [CA3868] 1431
Failure Code [CA3899] 1435
Failure Code [CA3911] 1437
Failure Code [CA3912] 1441
Failure Code [CA3932] 1443
Failure Code [CA3933] 1445
Failure Code [CA3934] 1447
Failure Code [CA3935] 1450
Failure Code [CA3936] 1452
Failure Code [CA4151] 1454
Failure Code [CA4152] 1458
Failure Code [CA4155] 1462
Failure Code [CA4156] 1465
Failure Code [CA4157] 1468
Failure Code [CA4158] 1470
Failure Code [CA4159] 1471
Failure Code [CA4161] 1472
Failure Code [CA4162] 1475
Failure Code [CA4163] 1478
Failure Code [CA4164] 1479
Failure Code [CA4165] 1481
Failure Code [CA4166] 1483
Failure Code [CA4168] 1484
Failure Code [CA4169] 1487
Failure Code [CA4171] 1489
Failure Code [CA4249] 1492
Failure Code [CA4251] 1494
Failure Code [CA4259] 1496
Failure Code [CA4261] 1499
Failure Code [CA4277] 1502
Failure Code [CA4281] 1506
Failure Code [CA4459] 1509
Failure Code [CA4461] 1512
Failure Code [CA4658] 1515
Failure Code [CA4731] 1519
Failure Code [CA4732] 1520
Failure Code [CA4739] 1521
Failure Code [CA4768] 1522
Failure Code [CA4769] 1524
Failure Code [CA4842] 1527
Failure Code [CA4952] 1531
Failure Code [CA5115] 1533
Failure Code [CA5179] 1536
Failure Code [CA5181] 1538
Failure Code [CA5383] 1540
Failure Code [D110KB] 1542
Failure Code [D19JKZ] 1544
Failure Code [D811MC] 1547
Failure Code [D862KA] 1548
Failure Code [D8ALKA] 1550
Failure Code [D8ALKB] 1553
Failure Code [D8AQKR] 1555
Failure Code [D8G1KT] 1562
Failure Code [D8G6KT] 1563
Failure Code [DA20MC] 1564
Failure Code [DA22KK] 1565
Failure Code [DA25KP] 1568
Failure Code [DA26KP] 1571
Failure Code [DA29KQ] 1573
Failure Code [DA2LKA] 1575
Failure Code [DA2LKB] 1578
Failure Code [DA2QKR] 1580
Failure Code [DA2RKR] 1589
Failure Code [DAF0KM] 1590
Failure Code [DAF0MB] 1591
Failure Code [DAF0MC] 1592
Failure Code [DAF8KB] 1593
Failure Code [DAF9KQ] 1595
Failure Code [DAFGMC] 1596
Failure Code [DAFLKA] 1597
Failure Code [DAFLKB] 1600
Failure Code [DAFQKR] 1602
Failure Code [DAZ9KQ] 1610
Failure Code [DAZQKR] 1611
Failure Code [DB2QKR] 1618
Failure Code [DB2RKR] 1626
Failure Code [DBP0KM] 1631
Failure Code [DBP0KT] 1632
Failure Code [DBP5KB] 1633
Failure Code [DBP5KY] 1636
Failure Code [DBPQKR] 1638
Failure Code [DDNRKA] 1646
Failure Code [DDNRKY] 1648
Failure Code [DDNS00] 1650
Failure Code [DFB1KZ] 1652
Failure Code [DFB2KZ] 1654
Failure Code [DFB3L8] 1656
Failure Code [DFB4L8] 1658
Failure Code [DFB5KZ] 1660
Failure Code [DFB6KZ] 1662
Failure Code [DGH2KA] 1664
Failure Code [DGH2KB] 1666
Failure Code [DHA4KA] 1668
Failure Code [DHAAMA] 1670
Failure Code [DHACMA] 1672
Failure Code [DHPAMA] 1674
Failure Code [DHPBMA] 1677
Failure Code [DHS3MA] 1680
Failure Code [DHS4MA] 1683
Failure Code [DHS8MA] 1686
Failure Code [DHS9MA] 1689
Failure Code [DHSAMA] 1692
Failure Code [DHSBMA] 1695
Failure Code [DHSCMA] 1698
Failure Code [DHSDMA] 1701
Failure Code [DHSFMA] 1704
Failure Code [DHSGMA] 1707
Failure Code [DHSHMA] 1710
Failure Code [DHSJMA] 1713
Failure Code [DHX1MA] 1716
Failure Code [DHZAMA] 1718
Failure Code [DHZCL8] 1722
Failure Code [DKR0MA] 1723
Failure Code [DKR1MA] 1726
Failure Code [DKULKA] 1729
Failure Code [DKULKB] 1731
Failure Code [DKULKY] 1733
Failure Code [DR10KA] 1735
Failure Code [DR12KA] 1738
Failure Code [DR20KA] 1740
Failure Code [DR21KX] 1742
Failure Code [DR30KA] 1744
Failure Code [DR31KX] 1746
Failure Code [DR40KA] 1748
Failure Code [DUMBKA] 1750
Failure Code [DUMBKB] 1753
Failure Code [DV20KB] 1755
Failure Code [DW43KA] 1757
Failure Code [DW43KB] 1759
Failure Code [DW43KY] 1761
Failure Code [DW45KA] 1763
Failure Code [DW45KB] 1766
Failure Code [DW45KY] 1769
Failure Code [DW4CKY] 1771
Failure Code [DW91KA] 1773
Failure Code [DW91KB] 1775
Failure Code [DW91KY] 1777
Failure Code [DWA2KA] 1779
Failure Code [DWA2KB] 1781
Failure Code [DWA2KY] 1783
Failure Code [DWK0KA] 1785
Failure Code [DWK0KB] 1787
Failure Code [DWK0KY] 1789
Failure Code [DWK2KA] 1791
Failure Code [DWK2KB] 1793
Failure Code [DWK2KY] 1795
Failure Code [DWK8KA] 1797
Failure Code [DWK8KB] 1799
Failure Code [DWK8KY] 1801
Failure Code [DWPUKA] 1803
Failure Code [DWPUKB] 1805
Failure Code [DWPUKY] 1807
Failure Code [DXA8KA] 1809
Failure Code [DXA8KB] 1811
Failure Code [DXA9KA] 1813
Failure Code [DXA9KB] 1815
Failure Code [DXE0KA] 1817
Failure Code [DXE0KB] 1819
Failure Code [DXE4KA] 1821
Failure Code [DXE4KB] 1823
Failure Code [DXE4KY] 1825
Failure Code [DXE5KA] 1827
Failure Code [DXE5KB] 1829
Failure Code [DXE6KA] 1831
Failure Code [DXE6KB] 1833
Failure Code [DXE7KA] 1835
Failure Code [DXE7KB] 1837
Failure Code [DXE7KY] 1839
Failure Code [DXE8KA] 1841
Failure Code [DXE8KB] 1843
Failure Code [DXE8KY] 1845
Failure Code [DXE9KA] 1847
Failure Code [DXE9KB] 1849
Failure Code [DXE9KY] 1851
Failure Code [DXEAKA] 1853
Failure Code [DXEAKB] 1855
Failure Code [DXEAKY] 1857
Failure Code [DXEKKA] 1859
Failure Code [DXEKKB] 1861
Failure Code [DXEKKY] 1863
Failure Code [DXELKA] 1865
Failure Code [DXELKB] 1867
Failure Code [DXELKY] 1869
Failure Code [DY20KA] 1871
Failure Code [DY20MA] 1873
Failure Code [DY2CKB] 1875
Failure Code [DY2DKB] 1878
Failure Code [DY2EKB] 1880
Failure Code [F311KA] 1882
Failure Code [F311KB] 1884
Failure Code [F312KA] 1886
Failure Code [F312KB] 1888
Failure Code [F313KA] 1890
Failure Code [F313KB] 1892
Failure Code [F314KA] 1895
Failure Code [F314KB] 1897
Failure Code [F315KB] 1899
Failure Code [F315KY] 1901
Failure Code [F316KB] 1903
Failure Code [F316KY] 1905
Failure Code [F318KB] 1907
Failure Code [F318KY] 1910
Failure Code [F31AKB] 1912
Failure Code [F31AKY] 1914
Failure Code [F31BKB] 1916
Failure Code [F31BKY] 1918
Failure Code [F31CKB] 1920
Failure Code [F31CKY] 1922
Failure Code [F31DKB] 1924
Failure Code [F31DKY] 1926
Failure Code [F31EKB] 1928
Failure Code [F31EKY] 1930
Troubleshooting of Electrical System (E-Mode) 1932
E-1 Engine Does Not Start (Engine Does Not Crank) 1932
E-2 Manual Preheating System Does Not Operate 1938
E-3 Automatic Preheating System Does Not Operate 1941
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1943
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1945
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1948
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1949
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1950
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1951
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1952
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1953
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1954
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1955
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1956
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1957
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1958
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1959
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1961
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1962
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1963
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1964
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1966
E-23 Some Areas of Machine Monitor Screen are Not Shown 1967
E-24 Function Switch Does Not Operate 1968
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1969
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1970
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1971
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1972
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1973
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1974
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1975
E-32 Alarm Buzzer Cannot be Canceled 1977
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1978
E-34 Service Mode Cannot be Selected 1979
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1980
E-36 All Work Equipment, Swing and Travel Do Not Lock 1983
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1985
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1988
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1990
E-40 One-Touch Power Maximizing Function is Not Cancelled 1993
E-41 Alarm Does Not Sound During Travel 1994
E-42 Alarm Does Not Stop When Machine Stops 1996
E-43 Horn Does Not Sound 1997
E-44 Horn Does Not Stop 2000
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 2002
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2003
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 2005
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2006
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2007
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 2008
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 2009
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2010
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2011
E-54 “Swing” is Not Shown Correctly with Monitoring Function 2012
E-55 “Travel” is Not Shown Correctly with Monitoring Function 2013
E-56 Service is Not Shown Correctly with Monitoring Function 2014
E-57 Attachment Hydraulic Circuit Cannot be Changed 2016
E-58 KOMTRAX System Does Not Operate Correctly 2017
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2018
Information Shown in Troubleshooting Table (H-Mode) 2018
System Chart of Hydraulic and Mechanical Systems 2019
Failure Mode and Cause Table 2021
H-1 All Work Equipment, Swing and Travel Do Not Work 2030
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2031
H-3 Fine Control Performance or Response is Unsatisfactory 2034
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2035
H-5 Engine Speed Drops Largely or Engine Stops 2036
H-6 Speed or Power of Boom is Low 2038
H-7 Arm Speed or Power is Low 2042
H-8 Bucket Speed or Power is Low 2047
H-9 Work Equipment Does Not Move in Single Operation 2050
H-10 Hydraulic Drift of Boom is Large 2051
H-11 Hydraulic Drift of Arm is Large 2053
H-12 Hydraulic Drift of Bucket is Large 2055
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2056
H-14 Time Lag of Work Equipment is Large 2057
H-15 One-Touch Power Maximizing Function Does Not Operate 2058
H-16 Attachment Circuit Cannot be Changed 2059
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2060
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2061
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2062
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 2063
H-21 Machine Does Not Travel Straight 2064
H-22 Machine is Not Steered Correctly or Steering Power is Low 2066
H-23 Travel Speed is Low 2069
H-24 One of Tracks Does Not Run 2071
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2072
H-26 Upper Structure Does Not Swing to Right and Left 2073
H-27 Upper Structure Swings Only to Right or Left 2074
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 2075
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2076
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2077
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2078
H-32 Shock is Large When Upper Structure Stops Swing Operation 2079
H-33 There is Large Unusual Noise When It Stops Swing Operation 2080
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2081
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2082
H-36 Quick coupler cylinder will not extend 2083
H-37 Quick coupler cylinder will not retract (but buzzer does not sound) 2085
H-38 Buzzer does not sound (but quick coupler cylinder does retract) 2087
H-39 Quick coupler cylinder extends and retracts slowly 2088
Troubleshooting of Engine (S-Mode) 2089
Information Shown in Troubleshooting Table (S-Mode) 2089
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2090
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2091
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2092
S-4 Engine Startability is Unsatisfactory 2094
S-5 Engine Does Not Pick Up Smoothly 2096
S-6 Engine Stops During Operation 2098
S-7 Engine Runs Rough or is Not Stable 2100
S-8 Engine Lacks Power 2101
S-9 KDPF Becomes Clogged in a Short Time 2103
S-10 Engine Oil Consumption is Excessive 2105
S-11 Oil Becomes Dirty Quickly 2106
S-12 Fuel Consumption is Excessive 2107
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2108
S-14 Oil Pressure Drops 2109
S-15 Fuel Mixes Into Engine Oil 2111
S-16 Water Mixes Into Engine Oil (Milky) 2112
S-17 Coolant Temperature Increases Too High (Overheating) 2113
S-18 Unusual Noise is Heard 2114
S-19 Vibration is Excessive 2115
S-20 Air Cannot be Bled from Fuel Circuit 2116
S-21 Active Regeneration is Done Frequently 2117
S-22 Active Regeneration Continues Long 2119
S-23 White Smoke is Exhausted During Active Regeneration 2120
S-24 DEF Consumption is Excessive 2121
S-25 There is Unusual Smell (Irritating Odor) 2123
S-26 Foreign Materials Enter DEF (DEF Increases) 2124
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 2155
Remove and Install Supply Pump Assembly 2155
How to Remove Supply Pump Assembly 2155
How to Install Supply Pump Assembly 2158
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 2175
How to Install Cylinder Head Assembly 2184
Remove and Install EGR Valve Assembly 2200
How to Remove EGR Valve Assembly 2200
How to Install EGR Valve Assembly 2201
Remove and Install EGR Cooler Assembly 2204
How to Remove EGR Cooler Assembly 2204
How to Install EGR Cooler Assembly 2207
Remove and Install Starter Assembly 2212
How to Remove Starting Motor Assembly 2212
How to Install Starting Motor Assembly 2214
Remove and Install Alternator Belt 2216
How to Remove Alternator Belt 2216
How to Install Alternator Belt 2218
Remove and Install Radiator Assembly 2220
How to Remove Radiator Assembly 2220
How to Install Radiator Assembly 2222
Remove and Install Hydraulic Oil Cooler Assembly 2224
How to Remove Hydraulic Oil Cooler Assembly 2224
How to Install Hydraulic Oil Cooler Assembly 2227
Remove and Install Aftercooler Assembly 2230
How to Remove Aftercooler Assembly 2230
How to Install Aftercooler Assembly 2231
Remove and Install Engine and Main Pump Assembly 2233
How to Remove Engine and Main Pump Assembly 2234
How to Install Engine and Main Pump Assembly 2242
Remove and Install Engine Front Oil Seal 2253
How to Remove Engine Front Oil Seal 2253
How to Install Engine Front Oil Seal 2256
Remove and Install Engine Rear Oil Seal 2260
How to Remove Engine Rear Oil Seal 2260
How to Install Engine Rear Oil Seal 2261
Remove and Install Fuel Cooler Assembly 2264
How to Remove Fuel Cooler Assembly 2264
How to Install Fuel Cooler Assembly 2265
Remove and Install Engine Hood Assembly 2266
How to Remove Engine Hood Assembly 2266
How to Install Engine Hood Assembly 2268
Remove and Install Fuel Tank Assembly 2274
How to Remove Fuel Tank Assembly 2274
How to Install Fuel Tank Assembly 2278
Remove and Install DEF Tank Assembly 2284
How to Remove DEF Tank Assembly 2284
How to Install DEF Tank Assembly 2289
Remove and Install DEF Tank Sensor Flange Assembly 2294
How to Remove DEF Tank Sensor Flange Assembly 2294
How to Install DEF Tank Sensor Flange Assembly 2299
Remove and Install DEF Tank Sensor 2305
How to Remove DEF Tank Sensor 2305
How to Install DEF Tank Sensor 2305
Remove and Install DEF Tank Strainer 2312
How to Remove DEF Tank Strainer 2312
How to Install DEF Tank Strainer 2312
Remove and Install DEF Tank Filler Port Filter 2313
How to Remove DEF Tank Filler Port Filter 2313
How to Install DEF Tank Filler Port Filter 2315
Remove and Install KDPF Assembly 2318
How to Remove KDPF Assembly 2318
How to Install KDPF Assembly 2320
Disassemble and Assemble KDPF Assembly 2322
How to Disassemble KDPF Assembly 2323
How to Assemble KDPF Assembly 2326
Remove and Install SCR Assembly 2331
How to Remove SCR Assembly 2331
How to Install SCR Assembly 2333
Remove and Install KDPF and SCR Assembly 2335
How to Remove KDPF and SCR Assembly 2335
How to Install KDPF and SCR Assembly 2341
Remove and Install KDPF and SCR Assembly Bracket 2347
How to Remove KDPF and SCR Assembly Bracket 2347
How to Install KDPF and SCR Assembly Bracket 2353
Remove and Install Bellows Pipe Assembly 2360
How to Remove Bellows Pipe Assembly 2360
How to Install Bellows Pipe Assembly 2362
Remove and Install KCCV Assembly 2366
How to Remove KCCV Assembly 2366
How to Install KCCV Assembly 2369
Remove and Install DEF Mixing Tube 2373
How to Remove DEF Mixing Tube 2373
How to Install DEF Mixing Tube 2378
Remove and Install DEF Injector 2383
How to Remove DEF Injector 2383
How to Install DEF Injector 2385
Remove and Install DEF Pump 2387
How to Remove DEF Pump 2387
How to Install DEF Pump 2389
Remove and Install DEF Hose 2392
How to Remove DEF Hose 2392
How to Install DEF Hose 2400
Remove and Install Air Cleaner Assembly 2406
How to Remove Air Cleaner Assembly 2406
How to Install Air Cleaner Assembly 2407
Remove and Install Air Conditioner Compressor Assembly 2409
How to Remove Air Conditioner Compressor Assembly 2409
How to Install Air Conditioner Compressor Assembly 2411
Remove and Install Air Conditioner Condenser Assembly 2414
How to Remove Air Conditioner Condenser Assembly 2414
How to Install Air Conditioner Condenser Assembly 2415
Power Train 2416
Remove and Install Travel Motor and Final Drive Assembly 2416
How to Remove Travel Motor and Final Drive Assembly 2416
How to Install Travel Motor and Final Drive Assembly 2417
Disassemble and Assemble Final Drive Assembly 2419
How to Disassemble Final Drive Assembly 2419
How to Assemble Final Drive Assembly 2423
Remove and Install Swing Motor and Swing Machinery Assembly 2432
How to Remove Swing Motor and Swing Machinery Assembly 2432
How to Install Swing Motor and Swing Machinery Assembly 2435
Disassemble and Assemble Swing Machinery Assembly 2438
How to Disassemble Swing Machinery Assembly 2438
How to Assemble Swing Machinery Assembly 2442
Remove and Install Swing Circle Assembly 2449
How to Remove Swing Circle Assembly 2449
How to Install Swing Circle Assembly 2449
Undercarriage and Frame 2451
Separate and Connect Track Assembly 2451
How to Separate Track Assembly 2451
How to Install Track Assembly 2453
Remove and Install Sprocket 2456
How to Remove Sprocket 2456
How to Install Sprocket 2456
Remove and Install Idler and Idler Cushion Assembly 2458
How to Remove Idler and Idler Cushion Assembly 2458
How to Install Idler and Idler Cushion Assembly 2459
Disassemble and Assemble Idler Assembly 2460
How to Disassemble Idler Assembly 2460
How to Assemble Idler Assembly 2461
Disassemble and Assemble Idler Cushion Assembly 2465
How to Disassemble Idler Cushion Assembly 2466
How to Assemble Idler Cushion Assembly 2467
Disassemble and Assemble Track Roller Assembly 2468
How to Disassemble Track Roller Assembly 2469
How to Assemble Track Roller Assembly 2470
Disassemble and Assemble Carrier Roller Assembly 2472
How to Disassemble Carrier Roller Assembly 2472
How to Assemble Carrier Roller Assembly 2474
Remove and Install Revolving Frame Assembly 2476
How to Remove Revolving Frame Assembly 2476
How to Install Revolving Frame Assembly 2478
Remove and Install Counterweight Assembly 2481
How to Remove Counterweight Assembly 2481
How to Install Counterweight Assembly 2484
Hydraulic System 2488
Remove and Install Center Swivel Joint Assembly 2488
How to Remove Center Swivel Joint Assembly 2488
How to Install Center Swivel Joint Assembly 2490
Disassemble and Assemble Center Swivel Joint Assembly 2493
How to Disassemble Center Swivel Joint Assembly 2494
How to Assemble Center Swivel Joint Assembly 2495
Remove and Install Hydraulic Tank Assembly 2496
How to Remove Hydraulic Tank Assembly 2496
How to Install Hydraulic Tank Assembly 2499
Remove and Install Main Pump Assembly 2503
How to Remove Main Pump Assembly 2503
How to Install Main Pump Assembly 2506
Remove and Install Control Valve Assembly 2510
How to Remove Control Valve Assembly 2510
How to Install Control Valve Assembly 2517
Disassemble and Assemble Control Valve Assembly 2525
How to Replace Pressure Compensation Valve Seal Ring 2525
How to Assemble Control Valve Assembly 2527
Disassemble and Assemble Work Equipment PPC Valve Assembly 2531
How to Disassemble Work Equipment PPC Valve Assembly 2531
How to Assemble Work Equipment PPC Valve Assembly 2531
Disassemble and Assemble Travel PPC Valve Assembly 2533
How to Disassemble Travel PPC Valve Assembly 2533
How to Assemble Travel PPC Valve Assembly 2534
Work Equipment 2536
Remove and Install Work Equipment Assembly 2536
How to Remove Work Equipment Assembly 2536
How to Install Work Equipment Assembly 2540
Remove and Install Boom Anti-drop Valve Assembly 2546
How to Remove Boom Anti-drop Valve Assembly 2546
How to Install Boom Anti-drop Valve Assembly 2548
Remove and Install Arm Anti-Drop Valve Assembly 2549
How to Remove Arm Anti-Drop Valve Assembly 2549
How to Install Arm Anti-Drop Valve Assembly 2551
Disassemble and Assemble Anti-Drop Valve Assembly 2552
How to Disassemble Anti-Drop Valve Assembly 2552
How to Assemble Anti-Drop Valve Assembly 2552
Disassemble and Assemble Work Equipment Cylinder Assembly 2553
How to Disassemble Work Equipment Cylinder Assembly 2553
How to Assemble Work Equipment Cylinder Assembly 2556
CAB Related Parts 2562
Remove and Install Operator Cab Assembly 2562
How to Remove Operator Cab Assembly 2562
How to Install Operator Cab Assembly 2568
Remove and Install Operator Cab Glass (Adhered Glass) 2575
How to Remove Operator Cab Glass (Adhered Glass) 2577
How to Install Operator Cab Glass (Adhered Glass) 2577
Remove and Install Front Window Assembly 2587
How to Remove Front Window Assembly 2587
How to Install Front Window Assembly 2590
Remove and Install Floor Frame Assembly 2596
How to Remove Floor Frame Assembly 2596
How to Install Floor Frame Assembly 2603
Remove and Install Air Conditioner Unit Assembly 2610
How to Remove Air Conditioner Unit Assembly 2610
How to Install Air Conditioner Unit Assembly 2616
Remove and Install Operator Seat 2623
How to Remove Operator Seat 2623
How to Install Operator Seat 2625
How to Remove and Install Seat Belt 2628
How to Remove Seat Belt 2628
How to Install Seatbelt 2629
Remove and Install Work Equipment Control Lever Assembly 2630
How to Remove Work Equipment Control Lever Assembly 2630
How to Install Work Equipment Control Lever Assembly 2636
Remove and Install Front Wiper Assembly 2645
How to Remove Front Wiper Assembly 2645
How to Install Front Wiper Assembly 2650
Electrical System 2659
Remove and Install Engine Controller Assembly 2659
How to Remove Engine Controller Assembly 2659
How to Install Engine Controller Assembly 2661
Remove and Install Pump Controller Assembly 2662
How to Remove Pump Controller Assembly 2662
How to Install Pump Controller Assembly 2666
Remove and Install KomVision Controller Assembly 2671
How to Remove KomVision Controller Assembly 2671
How to Install KomVision Controller Assembly 2672
Remove and Install Machine Monitor Assembly 2674
How to Remove Machine Monitor Assembly 2674
How to Install Machine Monitor Assembly 2677
Remove and Install Pump Swash Plate Sensor 2680
How to Remove Pump Swash Plate Sensor 2680
How to Install Pump Swash Plate Sensor 2681
Remove and Install Mass Air Flow and Temperature Sensor 2682
How to Remove Mass Air Flow and Temperature Sensor 2682
How to Install Mass Air Flow and Temperature Sensor 2683
Remove and Install KCCV Crankcase Pressure Sensor 2684
How to Remove KCCV Crankcase Pressure Sensor 2684
How to Install KCCV Crankcase Pressure Sensor 2685
Remove and Install SCR Temperature Sensor 2687
How to Remove SCR Temperature Sensor 2687
How to Install SCR Temperature Sensor 2689
Remove and Install KomVision Camera 2692
How to Remove KomVision Camera 2692
How to Install KomVision Camera 2695
Remove and Install Gateway Function Controller Assembly 2698
How to Remove Gateway Function Controller Assembly 2698
How to Install Gateway Function Controller Assembly 2703
Remove and Install Communication Terminal Wiring Harness 2708
How to Remove Communication Terminal Wiring Harness 2708
How to Install Communication Terminal Wiring Harness 2716
Remove and Install Communication Terminal 2725
How to Remove Communication Terminal 2725
How to Install Communication Terminal 2727
60 Maintenance Standard 2731
Table of Contents 2732
Engine and Cooling System 2733
Maintenance Standard for Engine Mount 2733
Maintenance Standard for Cooling System 2734
Power Train 2735
Maintenance Standard for Swing Circle 2735
Maintenance Standard for Swing Machinery 2736
Maintenance Standard for Final Drive 2738
Maintenance Standard for Sprocket 2740
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2741
Undercarriage and Frame 2742
Maintenance Standard for Track Frame and Idler Cushion 2742
Maintenance Standard for Idler 2744
Maintenance Standard for Track Roller 2746
Maintenance Standard for Carrier Roller 2747
Maintenance Standard for Track Shoes 2748
Maintenance Standard for Triple Shoes 2751
Maintenance Standard for Swamp Shoes 2752
Maintenance Standard for Road Liner 2753
Hydraulic System 2754
Maintenance Standard for Hydraulic Tank 2754
Maintenance Standard for Main Pump 2755
Maintenance Standard for LS-EPC Valve 2756
Maintenance Standard for PC-EPC Valve 2757
Maintenance Standard for Swing Motor 2758
Maintenance Standard for Travel Motor 2761
Maintenance Standard for Control Valve 2764
Maintenance Standard for Boom Anti-Drop Valve 2774
Maintenance Standard for Arm Anti-Drop Valve 2776
Maintenance Standard for Work Equipment and Swing PPC Valve 2778
Maintenance Standard for Travel PPC Valve 2781
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2784
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2785
Maintenance Standard for 2nd-Line Attachment PPC Valve 2787
Maintenance Standard for Solenoid Valve 2789
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2790
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2791
Maintenance Standard for Center Swivel Joint 2792
Work Equipment 2793
Maintenance Standard for Work Equipment Linkage 2793
Dimensions of Arm 2798
Dimensions of Bucket 2800
Maintenance Standard for Boom Cylinder 2802
Maintenance Standard for Boom Cylinder (Large Diameter Piston) 2803
Maintenance Standard for Arm Cylinder 2804
Maintenance Standard for Bucket Cylinder 2805
80 Appendix 2807
Table of Contents 2808
Precautions Before Work 2810
Air Conditioner System 2811
Precautions for Refrigerant 2811
Air Conditioner Component 2812
Specifications of Air Conditioner 2814
Structure and Function of Refrigeration Cycle 2815
Outline of Refrigeration Cycle 2816
Component Parts of Air Conditioner System 2818
Air Conditioner Unit 2818
Configuration Diagram of Air Conditioner Unit 2818
Function of Air Conditioner Unit 2820
Component Parts of Air Conditioner Unit 2822
Function of Evaporator as Air Conditioner Unit Component 2823
Function of Heater Core as Air Conditioner Unit Component 2823
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2823
Function of Servo Motor as Air Conditioner Unit Component 2823
Structure of Expansion Valve as Air Conditioner Unit Component 2824
Function of Expansion Valve as Air Conditioner Unit Component 2824
Operate Expansion Valve as Air Conditioner Unit Component 2824
Function of Dual Pressure Switch 2825
Air Conditioner Controller 2826
Structure of Air Conditioner Controller 2826
Compressor 2827
Structure of Compressor 2827
Specifications of Compressor 2827
Function of Compressor 2827
Condenser 2828
Structure of Condenser 2828
Specifications of Condenser 2828
Function of Condenser 2828
Air Conditioner Related Sensors 2830
Structure of Sunlight Sensor 2830
Function of Sunlight Sensor 2830
Structure of Outside Temperature Sensor 2830
Function of Outside Air Temperature Sensor 2830
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2832
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2834
System Diagram of Air Conditioner 2836
Input and Output Signals of Air Conditioner Controller 2837
Function of Air Conditioner Controller 2838
Locations of Air Conditioner Parts and Layout of Connectors 2839
Examine Air Leakage (Duct) 2843
How to Examine Air Leakage (Duct) 2843
Examine Air Conditioner with Self-Diagnosis Function 2845
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2846
Examine Vent (Mode) Changeover 2847
How to Examine Vent (Mode) Changeover 2847
Examine Fresh/Recirc Air Changeover 2849
How to Examine Fresh/Recirc Air Changeover 2849
Examine Sunlight Sensor 2850
How to Examine Sunlight Sensor 2850
Examine Refrigerant (Dual) Pressure Switch 2851
How to Examine Refrigerant (Dual) Pressure Switch 2851
Examine Relay 2852
How to Examine Relay 2852
Air Conditioner Troubleshooting Chart 1 2853
Air Conditioner Troubleshooting Chart 2 2854
Information Shown in Troubleshooting Table 2857
Failure Code [879AKA] 2858
Failure Code [879AKB] 2859
Failure Code [879BKA] 2860
Failure Code [879BKB] 2862
Failure Code [879CKA] 2864
Failure Code [879CKB] 2865
Failure Code [879DKZ] 2866
Failure Code [879EMC] 2868
Failure Code [879FMC] 2869
Failure Code [879GKX] 2870
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2872
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2874
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2877
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2879
Troubleshooting by Gauge Pressure 2881
Connect Service Tool 2884
How to Connect Service Tool 2884
Precautions for Disconnection and Connection of Air Conditioner Piping 2886
Handle Compressor Oil 2888
How to Replace Desiccant 2890
90 Circuit Diagrams 2893
Table of Contents 2894
Hydraulic Circuit Diagram 2895
Symbols Used in Hydraulic Circuit Diagram 2895
Hydraulic Circuit Diagram (1/2) 2899
Hydraulic Circuit Diagram (2/2) 2901
Electrical Circuit Diagram 2903
Symbols Used in Electric Circuit Diagram 2903
Electrical Circuit Diagram (1/10) 2907
Electrical Circuit Diagram (2/10) 2909
Electrical Circuit Diagram (3/10) 2911
Electrical Circuit Diagram (4/10) 2913
Electrical Circuit Diagram (5/10) 2915
Electrical Circuit Diagram (6/10) 2917
Electrical Circuit Diagram (7/10) 2919
Electrical Circuit Diagram (8/10) 2921
Electrical Circuit Diagram (9/10) 2923
Electrical Circuit Diagram (10/10) 2925
Index 2927

S.V  21/12/24