Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06808-10 PDF

Description

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06808-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06808-10 – PDF DOWNLOAD 

Language : English
Pages : 2928
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06808-10 – PDF DOWNLOAD 

SERIAL NUMBERS 35151 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 PC290LC-11 Hydraulic Excavator Shop Manual SEN06808-10 – PDF DOWNLOAD 

SERIAL NUMBERS 35151 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC290LC-11 93
Working Range Drawings 95
Working Range: PC290LC-11 95
Specifications 96
Specifications: PC290LC-11 96
Weight Table 99
Weight Table: PC290LC-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
Attachment Bypass Solenoid Valve 410
Pilot Circuit Accumulator 412
Attachment Circuit Accumulator 413
Swing System 414
Layout Drawing of Swing System 414
Swing Control System Diagram 418
Function of Swing Control System 418
Component Parts of Swing System 422
Swing Motor 422
Swing Machinery 433
Swing Circle 434
Travel System 436
Layout Drawing of Travel System 436
System Diagram of Travel Control System 440
Function of Travel Control System 440
Component Parts of Travel System 442
Travel Motor 442
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: PC290LC-11 473
Standard Value Table for Machine 477
Standard Value Table for Machine: PC290LC-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
Bleed Air from Coolant Circuit of DEF Tank 595
How to Bleed Air from Coolant Circuit of DEF Tank 595
Clean DEF Pump 597
How to Clean DEF Pump 597
Power Train 603
Examine Swing Circle Bearing Clearance 603
How to Examine Swing Circle Bearing Clearance 603
Undercarriage and Frame 604
Examine and Adjust Track Tension 604
How to Examine Track Tension 604
How to Adjust Track Tension 604
Hydraulic System 606
Release Remained Pressure in Hydraulic Circuit 606
How to Release Remained Pressure in Hydraulic System 606
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 612
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 613
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 619
Examine Oil Pressure of Control Circuit 622
How to Examine Oil Pressure in Control Circuit 622
Examine and adjust oil pressure in pump PC control circuit 624
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 624
Examine PC-EPC Valve Outlet Pressure 625
How to Adjust Oil Pressure in Pump PC Control Circuit 626
Examine and Adjust Oil Pressure in Pump LS Control Circuit 628
How to Examine LS Differential Pressure with Machine Monitor 628
How to Examine LS Differential Pressure by Testing Tool 629
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 632
How to Examine LS-EPC Valve Outlet Pressure 633
How to Adjust LS Valve 634
Examine Outlet Pressure of Solenoid Valve 635
How to Examine Outlet Pressure of Solenoid Valve 635
Operating Condition of Solenoid Valve 636
Examine PPC Valve Outlet Pressure 639
How to Examine Outlet Pressure in PPC Valve 639
Adjust Play of Work Equipment and Swing PPC Valves 641
How to Adjust Play of Work Equipment and Swing PPC Valves 641
Measure and Adjust Quick Coupler Control Valve Output Pressure 642
Examine Pump Swash Plate Sensor 644
How to Examine pump swash plate sensor 644
Examine Parts Which Cause Hydraulic Drift of Work Equipment 645
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 645
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 645
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 646
Examine Oil Leakage 647
How to Examine Oil Leakage from Boom Cylinder 647
How to Examine Oil Leakage from Arm Cylinder 647
How to Examine Oil Leakage from Bucket Cylinder 648
How to Examine Oil Leakage from Swing Motor 649
How to Examine Oil Leakage from Travel Motor 649
Bleed Air from Hydraulic System 650
How to Bleed Air from Hydraulic System 652
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 654
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 654
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 658
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 658
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 662
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 662
CAB Related Parts 669
Examine CAB Tipping Stopper 669
How to Examine Cab Tipping Stopper 669
How to Adjust Mirrors 670
Procedure to Adjust Machine Left Front Mirror (A) 670
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 671
Procedure to Adjust Machine Right Front Mirror (B) 672
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 673
Procedure to Adjust Machine Right Side Mirror (C) 674
Electrical System 676
Set and Operate Machine Monitor 676
Operator Mode 679
Function to Show Technician Identification Status Screen 680
Function to Show Operator Identification Input Screen 680
Examine Function by LCD (Liquid Crystal Display) 681
Examine Function of Service Meter 681
Usage Limitation and Maintenance Password Change Function 681
Service Mode 684
How to Operate Service Mode 684
How to See Pre-defined Monitoring Information 686
How to Examine Self-Define Monitor Information 693
Abnormality Record Menu 704
How to See Maintenance Record 708
Maintenance Mode Setting 709
How to Set Phone Number Entry 713
Default Menu 714
Diagnostic Tests Menu 726
Adjustment Menu 735
No-Injection Cranking Operation 756
KOMTRAX Settings Menu 757
How to Show Service Message 760
How to Start Up KOMTRAX System 762
Adjust Rearview Camera Angle 767
How to Adjust Rearview Camera Angle 767
Adjust KomVision Camera Angle 770
How to Adjust KomVision Camera Angle 771
Adjust KomVision Related Function 775
Setting of KomVision (Main Setting) 775
Setting of KomVision (Camera Setting) 777
Setting of KomVision (Camera Calibration) 779
KomVision screen – Check 12 m visibility 792
Set Region of Bluetooth(R) Compatible Radio 795
How to Set Region of Bluetooth(R) Compatible Radio 795
Handle Voltage Circuit of Engine Controller 797
Handle Battery Isolator Switch 798
Examine Diodes 799
How to Examine Diodes by Digital Tester 799
How to Examine Diodes by Analog Tester 799
Pm Clinic 800
Pm Clinic Service 800
Pm Clinic Check Sheet 804
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] 1382
Failure Code [CA3578] 1384
Failure Code [CA3582] 1386
Failure Code [CA3583] 1392
Failure Code [CA3596] 1394
Failure Code [CA3649] 1396
Failure Code [CA3681] 1398
Failure Code [CA3682] 1403
Failure Code [CA3713] 1408
Failure Code [CA3717] 1411
Failure Code [CA3718] 1412
Failure Code [CA3725] 1413
Failure Code [CA3741] 1416
Failure Code [CA3748] 1417
Failure Code [CA3751] 1419
Failure Code [CA3755] 1421
Failure Code [CA3866] 1423
Failure Code [CA3867] 1427
Failure Code [CA3868] 1430
Failure Code [CA3899] 1434
Failure Code [CA3911] 1436
Failure Code [CA3912] 1440
Failure Code [CA3932] 1442
Failure Code [CA3933] 1444
Failure Code [CA3934] 1446
Failure Code [CA3935] 1449
Failure Code [CA3936] 1451
Failure Code [CA4151] 1453
Failure Code [CA4152] 1457
Failure Code [CA4155] 1461
Failure Code [CA4156] 1464
Failure Code [CA4157] 1467
Failure Code [CA4158] 1469
Failure Code [CA4159] 1470
Failure Code [CA4161] 1471
Failure Code [CA4162] 1474
Failure Code [CA4163] 1477
Failure Code [CA4164] 1478
Failure Code [CA4165] 1480
Failure Code [CA4166] 1482
Failure Code [CA4168] 1483
Failure Code [CA4169] 1486
Failure Code [CA4171] 1488
Failure Code [CA4249] 1491
Failure Code [CA4251] 1493
Failure Code [CA4259] 1495
Failure Code [CA4261] 1498
Failure Code [CA4277] 1501
Failure Code [CA4281] 1505
Failure Code [CA4459] 1508
Failure Code [CA4461] 1511
Failure Code [CA4658] 1514
Failure Code [CA4731] 1518
Failure Code [CA4732] 1519
Failure Code [CA4739] 1520
Failure Code [CA4768] 1521
Failure Code [CA4769] 1523
Failure Code [CA4842] 1526
Failure Code [CA4952] 1530
Failure Code [CA5115] 1532
Failure Code [CA5179] 1535
Failure Code [CA5181] 1537
Failure Code [CA5383] 1539
Failure Code [D110KB] 1541
Failure Code [D19JKZ] 1543
Failure Code [D811MC] 1546
Failure Code [D862KA] 1547
Failure Code [D8ALKA] 1549
Failure Code [D8ALKB] 1552
Failure Code [D8AQKR] 1554
Failure Code [D8G1KT] 1561
Failure Code [D8G6KT] 1562
Failure Code [DA20MC] 1563
Failure Code [DA22KK] 1564
Failure Code [DA25KP] 1567
Failure Code [DA26KP] 1570
Failure Code [DA29KQ] 1572
Failure Code [DA2LKA] 1574
Failure Code [DA2LKB] 1577
Failure Code [DA2QKR] 1579
Failure Code [DA2RKR] 1588
Failure Code [DAF0KM] 1589
Failure Code [DAF0MB] 1590
Failure Code [DAF0MC] 1591
Failure Code [DAF8KB] 1592
Failure Code [DAF9KQ] 1596
Failure Code [DAFGMC] 1597
Failure Code [DAFLKA] 1598
Failure Code [DAFLKB] 1601
Failure Code [DAFQKR] 1603
Failure Code [DAZ9KQ] 1611
Failure Code [DAZQKR] 1612
Failure Code [DB2QKR] 1619
Failure Code [DB2RKR] 1627
Failure Code [DBP0KM] 1632
Failure Code [DBP0KT] 1633
Failure Code [DBP5KB] 1634
Failure Code [DBP5KY] 1637
Failure Code [DBPQKR] 1639
Failure Code [DDNRKA] 1647
Failure Code [DDNRKY] 1649
Failure Code [DDNS00] 1651
Failure Code [DFB1KZ] 1653
Failure Code [DFB2KZ] 1655
Failure Code [DFB3L8] 1657
Failure Code [DFB4L8] 1659
Failure Code [DFB5KZ] 1661
Failure Code [DFB6KZ] 1663
Failure Code [DGH2KA] 1665
Failure Code [DGH2KB] 1667
Failure Code [DHA4KA] 1669
Failure Code [DHAAMA] 1671
Failure Code [DHACMA] 1673
Failure Code [DHPAMA] 1675
Failure Code [DHPBMA] 1678
Failure Code [DHS3MA] 1681
Failure Code [DHS4MA] 1684
Failure Code [DHS8MA] 1687
Failure Code [DHS9MA] 1690
Failure Code [DHSAMA] 1693
Failure Code [DHSBMA] 1696
Failure Code [DHSCMA] 1699
Failure Code [DHSDMA] 1702
Failure Code [DHSFMA] 1705
Failure Code [DHSGMA] 1708
Failure Code [DHSHMA] 1711
Failure Code [DHSJMA] 1714
Failure Code [DHX1MA] 1717
Failure Code [DHZAMA] 1719
Failure Code [DHZCL8] 1723
Failure Code [DKR0MA] 1724
Failure Code [DKR1MA] 1727
Failure Code [DKULKA] 1730
Failure Code [DKULKB] 1732
Failure Code [DKULKY] 1734
Failure Code [DR10KA] 1736
Failure Code [DR12KA] 1739
Failure Code [DR20KA] 1741
Failure Code [DR21KX] 1743
Failure Code [DR30KA] 1745
Failure Code [DR31KX] 1747
Failure Code [DR40KA] 1749
Failure Code [DUMBKA] 1751
Failure Code [DUMBKB] 1754
Failure Code [DV20KB] 1756
Failure Code [DW43KA] 1758
Failure Code [DW43KB] 1760
Failure Code [DW43KY] 1762
Failure Code [DW45KA] 1764
Failure Code [DW45KB] 1767
Failure Code [DW45KY] 1770
Failure Code [DW4CKY] 1772
Failure Code [DW91KA] 1774
Failure Code [DW91KB] 1776
Failure Code [DW91KY] 1778
Failure Code [DWA2KA] 1780
Failure Code [DWA2KB] 1782
Failure Code [DWA2KY] 1784
Failure Code [DWK0KA] 1786
Failure Code [DWK0KB] 1788
Failure Code [DWK0KY] 1790
Failure Code [DWK2KA] 1792
Failure Code [DWK2KB] 1794
Failure Code [DWK2KY] 1796
Failure Code [DWK8KA] 1798
Failure Code [DWK8KB] 1800
Failure Code [DWK8KY] 1802
Failure Code [DXA8KA] 1804
Failure Code [DXA8KB] 1806
Failure Code [DXA9KA] 1808
Failure Code [DXA9KB] 1810
Failure Code [DXE0KA] 1812
Failure Code [DXE0KB] 1814
Failure Code [DXE4KA] 1816
Failure Code [DXE4KB] 1818
Failure Code [DXE4KY] 1820
Failure Code [DXE5KA] 1822
Failure Code [DXE5KB] 1824
Failure Code [DXE6KA] 1826
Failure Code [DXE6KB] 1828
Failure Code [DXE7KA] 1830
Failure Code [DXE7KB] 1832
Failure Code [DXE7KY] 1834
Failure Code [DXE8KA] 1836
Failure Code [DXE8KB] 1838
Failure Code [DXE8KY] 1840
Failure Code [DXE9KA] 1842
Failure Code [DXE9KB] 1844
Failure Code [DXE9KY] 1846
Failure Code [DXEAKA] 1848
Failure Code [DXEAKB] 1850
Failure Code [DXEAKY] 1852
Failure Code [DXEKKA] 1854
Failure Code [DXEKKB] 1856
Failure Code [DXEKKY] 1858
Failure Code [DXELKA] 1860
Failure Code [DXELKB] 1862
Failure Code [DXELKY] 1864
Failure Code [DY20KA] 1866
Failure Code [DY20MA] 1868
Failure Code [DY2CKB] 1870
Failure Code [DY2DKB] 1873
Failure Code [DY2EKB] 1875
Failure Code [F311KA] 1877
Failure Code [F311KB] 1879
Failure Code [F312KA] 1881
Failure Code [F312KB] 1883
Failure Code [F313KA] 1885
Failure Code [F313KB] 1887
Failure Code [F314KA] 1890
Failure Code [F314KB] 1892
Failure Code [F315KB] 1894
Failure Code [F315KY] 1896
Failure Code [F316KB] 1898
Failure Code [F316KY] 1900
Failure Code [F318KB] 1902
Failure Code [F318KY] 1905
Failure Code [F31AKB] 1907
Failure Code [F31AKY] 1909
Failure Code [F31BKB] 1911
Failure Code [F31BKY] 1913
Failure Code [F31CKB] 1915
Failure Code [F31CKY] 1917
Failure Code [F31DKB] 1919
Failure Code [F31DKY] 1921
Failure Code [F31EKB] 1923
Failure Code [F31EKY] 1925
Troubleshooting of Electrical System (E-Mode) 1927
E-1 Engine Does Not Start (Engine Does Not Crank) 1927
E-2 Manual Preheating System Does Not Operate 1933
E-3 Automatic Preheating System Does Not Operate 1936
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1938
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1940
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1943
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1944
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1945
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1946
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1947
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1948
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1949
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1950
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1951
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1952
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1953
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1954
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1956
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1957
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1958
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1959
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1961
E-23 Some Areas of Machine Monitor Screen are Not Shown 1962
E-24 Function Switch Does Not Operate 1963
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1964
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1965
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1966
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1967
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1968
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1969
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1970
E-32 Alarm Buzzer Cannot be Canceled 1972
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1973
E-34 Service Mode Cannot be Selected 1974
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1975
E-36 All Work Equipment, Swing and Travel Do Not Lock 1978
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1980
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1983
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 1985
E-40 One-Touch Power Maximizing Function is Not Cancelled 1988
E-41 Alarm Does Not Sound During Travel 1989
E-42 Alarm Does Not Stop When Machine Stops 1991
E-43 Horn Does Not Sound 1992
E-44 Horn Does Not Stop 1995
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1997
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1998
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 2000
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2001
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2002
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 2003
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 2004
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2005
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2006
E-54 “Swing” is Not Shown Correctly with Monitoring Function 2007
E-55 “Travel” is Not Shown Correctly with Monitoring Function 2008
E-56 Service is Not Shown Correctly with Monitoring Function 2009
E-57 Attachment Hydraulic Circuit Cannot be Changed 2011
E-58 KOMTRAX System Does Not Operate Correctly 2012
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2013
Information Shown in Troubleshooting Table (H-Mode) 2013
System Chart of Hydraulic and Mechanical Systems 2014
Failure Mode and Cause Table 2016
H-1 All Work Equipment, Swing and Travel Do Not Work 2025
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2026
H-3 Fine Control Performance or Response is Unsatisfactory 2029
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2030
H-5 Engine Speed Drops Largely or Engine Stops 2031
H-6 Speed or Power of Boom is Low 2033
H-7 Arm Speed or Power is Low 2037
H-8 Bucket Speed or Power is Low 2042
H-9 Work Equipment Does Not Move in Single Operation 2045
H-10 Hydraulic Drift of Boom is Large 2046
H-11 Hydraulic Drift of Arm is Large 2048
H-12 Hydraulic Drift of Bucket is Large 2050
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2051
H-14 Time Lag of Work Equipment is Large 2052
H-15 One-Touch Power Maximizing Function Does Not Operate 2053
H-16 Attachment Circuit Cannot be Changed 2054
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2055
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2056
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2057
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 2058
H-21 Machine Does Not Travel Straight 2059
H-22 Machine is Not Steered Correctly or Steering Power is Low 2061
H-23 Travel Speed is Low 2064
H-24 One of Tracks Does Not Run 2066
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2067
H-26 Upper Structure Does Not Swing to Right and Left 2068
H-27 Upper Structure Swings Only to Right or Left 2069
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 2070
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2071
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2072
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2073
H-32 Shock is Large When Upper Structure Stops Swing Operation 2074
H-33 There is Large Unusual Noise When It Stops Swing Operation 2075
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2076
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2077
H-36 Quick coupler cylinder will not extend 2078
H-37 Quick coupler cylinder will not retract (but buzzer does not sound) 2080
H-38 Buzzer does not sound (but quick coupler cylinder does retract) 2082
H-39 Quick coupler cylinder extends and retracts slowly 2083
Troubleshooting of Engine (S-Mode) 2084
Information Shown in Troubleshooting Table (S-Mode) 2084
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2085
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2086
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2087
S-4 Engine Startability is Unsatisfactory 2089
S-5 Engine Does Not Pick Up Smoothly 2091
S-6 Engine Stops During Operation 2093
S-7 Engine Runs Rough or is Not Stable 2095
S-8 Engine Lacks Power 2096
S-9 KDPF Becomes Clogged in a Short Time 2098
S-10 Engine Oil Consumption is Excessive 2100
S-11 Oil Becomes Dirty Quickly 2101
S-12 Fuel Consumption is Excessive 2102
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2103
S-14 Oil Pressure Drops 2104
S-15 Fuel Mixes Into Engine Oil 2106
S-16 Water Mixes Into Engine Oil (Milky) 2107
S-17 Coolant Temperature Increases Too High (Overheating) 2108
S-18 Unusual Noise is Heard 2109
S-19 Vibration is Excessive 2110
S-20 Air Cannot be Bled from Fuel Circuit 2111
S-21 Active Regeneration is Done Frequently 2112
S-22 Active Regeneration Continues Long 2114
S-23 White Smoke is Exhausted During Active Regeneration 2115
S-24 DEF Consumption is Excessive 2116
S-25 There is Unusual Smell (Irritating Odor) 2118
S-26 Foreign Materials Enter DEF (DEF Increases) 2119
50 Disassembly and Assembly 2121
Table of Contents 2122
Precautions Before Work 2127
Related Information on Disassembly and Assembly 2128
How to Read This Manual 2128
Coating Materials List 2129
Special Tool List 2134
Sketches of Special Tools 2146
Engine and Cooling System 2151
Remove and Install Supply Pump Assembly 2151
How to Remove Supply Pump Assembly 2151
How to Install Supply Pump Assembly 2154
Remove and Install Injector Assembly 2157
How to Remove Injector Assembly 2157
How to Install Injector Assembly 2162
Remove and Install Cylinder Head Assembly 2170
How to Remove Cylinder Head Assembly 2170
How to Install Cylinder Head Assembly 2179
Remove and Install EGR Valve Assembly 2195
How to Remove EGR Valve Assembly 2195
How to Install EGR Valve Assembly 2196
Remove and Install EGR Cooler Assembly 2199
How to Remove EGR Cooler Assembly 2199
How to Install EGR Cooler Assembly 2202
Remove and Install Starter Assembly 2207
How to Remove Starting Motor Assembly 2207
How to Install Starting Motor Assembly 2208
Remove and Install Alternator Belt 2211
How to Remove Alternator Belt 2211
How to Install Alternator Belt 2213
Remove and Install Radiator Assembly 2215
How to Remove Radiator Assembly 2215
How to Install Radiator Assembly 2217
Remove and Install Hydraulic Oil Cooler Assembly 2219
How to Remove Hydraulic Oil Cooler Assembly 2219
How to Install Hydraulic Oil Cooler Assembly 2222
Remove and Install Aftercooler Assembly 2225
How to Remove Aftercooler Assembly 2225
How to Install Aftercooler Assembly 2226
Remove and Install Engine and Main Pump Assembly 2228
How to Remove Engine and Main Pump Assembly 2229
How to Install Engine and Main Pump Assembly 2237
Remove and Install Engine Front Oil Seal 2248
How to Remove Engine Front Oil Seal 2248
How to Install Engine Front Oil Seal 2251
Remove and Install Engine Rear Oil Seal 2255
How to Remove Engine Rear Oil Seal 2255
How to Install Engine Rear Oil Seal 2256
Remove and Install Fuel Cooler Assembly 2259
How to Remove Fuel Cooler Assembly 2259
How to Install Fuel Cooler Assembly 2259
Remove and Install Engine Hood Assembly 2261
How to Remove Engine Hood Assembly 2261
How to Install Engine Hood Assembly 2263
Remove and Install Fuel Tank Assembly 2268
How to Remove Fuel Tank Assembly 2268
How to Install Fuel Tank Assembly 2272
Remove and Install DEF Tank Assembly 2278
How to Remove DEF Tank Assembly 2278
How to Install DEF Tank Assembly 2283
Remove and Install DEF Tank Sensor Flange Assembly 2289
How to Remove DEF Tank Sensor Flange Assembly 2289
How to Install DEF Tank Sensor Flange Assembly 2294
Remove and Install DEF Tank Sensor 2300
How to Remove DEF Tank Sensor 2300
How to Install DEF Tank Sensor 2300
Remove and Install DEF Tank Strainer 2307
How to Remove DEF Tank Strainer 2307
How to Install DEF Tank Strainer 2307
Remove and Install DEF Tank Filler Port Filter 2308
How to Remove DEF Tank Filler Port Filter 2308
How to Install DEF Tank Filler Port Filter 2310
Remove and Install KDPF Assembly 2313
How to Remove KDPF Assembly 2313
How to Install KDPF Assembly 2315
Disassemble and Assemble KDPF Assembly 2317
How to Disassemble KDPF Assembly 2318
How to Assemble KDPF Assembly 2321
Remove and Install SCR Assembly 2326
How to Remove SCR Assembly 2326
How to Install SCR Assembly 2328
Remove and Install KDPF and SCR Assembly 2330
How to Remove KDPF and SCR Assembly 2330
How to Install KDPF and SCR Assembly 2336
Remove and Install KDPF and SCR Assembly Bracket 2342
How to Remove KDPF and SCR Assembly Bracket 2342
How to Install KDPF and SCR Assembly Bracket 2349
Remove and Install Bellows Pipe Assembly 2357
How to Remove Bellows Pipe Assembly 2357
How to Install Bellows Pipe Assembly 2359
Remove and Install KCCV Assembly 2363
How to Remove KCCV Assembly 2363
How to Install KCCV Assembly 2365
Remove and Install DEF Mixing Tube 2370
How to Remove DEF Mixing Tube 2370
How to Install DEF Mixing Tube 2375
Remove and Install DEF Injector 2380
How to Remove DEF Injector 2380
How to Install DEF Injector 2382
Remove and Install DEF Pump 2384
How to Remove DEF Pump 2384
How to Install DEF Pump 2386
Remove and Install DEF Hose 2389
How to Remove DEF Hose 2389
How to Install DEF Hose 2397
Remove and Install Air Cleaner Assembly 2403
How to Remove Air Cleaner Assembly 2403
How to Install Air Cleaner Assembly 2404
Remove and Install Air Conditioner Compressor Assembly 2406
How to Remove Air Conditioner Compressor Assembly 2406
How to Install Air Conditioner Compressor Assembly 2408
Remove and Install Air Conditioner Condenser Assembly 2411
How to Remove Air Conditioner Condenser Assembly 2411
How to Install Air Conditioner Condenser Assembly 2412
Power Train 2413
Remove and Install Travel Motor and Final Drive Assembly 2413
How to Remove Travel Motor and Final Drive Assembly 2413
How to Install Travel Motor and Final Drive Assembly 2414
Disassemble and Assemble Final Drive Assembly 2415
How to Disassemble Final Drive Assembly 2415
How to Assemble Final Drive Assembly 2419
Remove and Install Swing Motor and Swing Machinery Assembly 2428
How to Remove Swing Motor and Swing Machinery Assembly 2428
How to Install Swing Motor and Swing Machinery Assembly 2430
Disassemble and Assemble Swing Machinery Assembly 2434
How to Disassemble Swing Machinery Assembly 2434
How to Assemble Swing Machinery Assembly 2438
Remove and Install Swing Circle Assembly 2445
How to Remove Swing Circle Assembly 2445
How to Install Swing Circle Assembly 2445
Undercarriage and Frame 2447
Separate and Connect Track Assembly 2447
How to Separate Track Assembly 2447
How to Install Track Assembly 2449
Remove and Install Sprocket 2452
How to Remove Sprocket 2452
How to Install Sprocket 2452
Remove and Install Idler and Idler Cushion Assembly 2454
How to Remove Idler and Idler Cushion Assembly 2454
How to Install Idler and Idler Cushion Assembly 2455
Disassemble and Assemble Idler Assembly 2456
How to Disassemble Idler Assembly 2456
How to Assemble Idler Assembly 2457
Disassemble and Assemble Idler Cushion Assembly 2461
How to Disassemble Idler Cushion Assembly 2462
How to Assemble Idler Cushion Assembly 2462
Disassemble and Assemble Track Roller Assembly 2464
How to Disassemble Track Roller Assembly 2465
How to Assemble Track Roller Assembly 2466
Disassemble and Assemble Carrier Roller Assembly 2468
How to Disassemble Carrier Roller Assembly 2468
How to Assemble Carrier Roller Assembly 2469
Remove and Install Revolving Frame Assembly 2472
How to Remove Revolving Frame Assembly 2472
How to Install Revolving Frame Assembly 2474
Remove and Install Counterweight Assembly 2476
How to Remove Counterweight Assembly 2476
How to Install Counterweight Assembly 2479
Hydraulic System 2483
Remove and Install Center Swivel Joint Assembly 2483
How to Remove Center Swivel Joint Assembly 2483
How to Install Center Swivel Joint Assembly 2485
Disassemble and Assemble Center Swivel Joint Assembly 2488
How to Disassemble Center Swivel Joint Assembly 2488
How to Assemble Center Swivel Joint Assembly 2489
Remove and Install Hydraulic Tank Assembly 2491
How to Remove Hydraulic Tank Assembly 2491
How to Install Hydraulic Tank Assembly 2494
Remove and Install Main Pump Assembly 2498
How to Remove Main Pump Assembly 2498
How to Install Main Pump Assembly 2501
Remove and Install Control Valve Assembly 2505
How to Remove Control Valve Assembly 2505
Disassemble and Assemble Control Valve Assembly 2510
How to Replace Pressure Compensation Valve Seal Ring 2510
How to Assemble Control Valve Assembly 2511
Disassemble and Assemble Work Equipment PPC Valve Assembly 2515
How to Disassemble Work Equipment PPC Valve Assembly 2515
How to Assemble Work Equipment PPC Valve Assembly 2515
Disassemble and Assemble Travel PPC Valve Assembly 2517
How to Disassemble Travel PPC Valve Assembly 2517
How to Assemble Travel PPC Valve Assembly 2518
Work Equipment 2520
Remove and Install Work Equipment Assembly 2520
How to Remove Work Equipment Assembly 2520
How to Install Work Equipment Assembly 2524
Remove and Install Boom Anti-drop Valve Assembly 2530
How to Remove Boom Anti-drop Valve Assembly 2530
How to Install Boom Anti-drop Valve Assembly 2532
Remove and Install Arm Anti-Drop Valve Assembly 2533
How to Remove Arm Anti-Drop Valve Assembly 2533
How to Install Arm Anti-Drop Valve Assembly 2535
Disassemble and Assemble Anti-Drop Valve Assembly 2536
How to Disassemble Anti-Drop Valve Assembly 2536
How to Assemble Anti-Drop Valve Assembly 2536
Disassemble and Assemble Work Equipment Cylinder Assembly 2537
How to Disassemble Work Equipment Cylinder Assembly 2537
How to Assemble Work Equipment Cylinder Assembly 2540
CAB Related Parts 2546
Remove and Install Operator Cab Assembly 2546
How to Remove Operator Cab Assembly 2546
How to Install Operator Cab Assembly 2552
Remove and Install Operator Cab Glass (Adhered Glass) 2559
How to Remove Operator Cab Glass (Adhered Glass) 2561
How to Install Operator Cab Glass (Adhered Glass) 2561
Remove and Install Front Window Assembly 2571
How to Remove Front Window Assembly 2571
How to Install Front Window Assembly 2574
Remove and Install Floor Frame Assembly 2580
How to Remove Floor Frame Assembly 2580
How to Install Floor Frame Assembly 2587
Remove and Install Air Conditioner Unit Assembly 2594
How to Remove Air Conditioner Unit Assembly 2594
How to Install Air Conditioner Unit Assembly 2600
Remove and Install Operator Seat 2607
How to Remove Operator Seat 2607
How to Install Operator Seat 2609
How to Remove and Install Seat Belt 2612
How to Remove Seat Belt 2612
How to Install Seatbelt 2613
Remove and Install Work Equipment Control Lever Assembly 2614
How to Remove Work Equipment Control Lever Assembly 2614
How to Install Work Equipment Control Lever Assembly 2620
Remove and Install Front Wiper Assembly 2629
How to Remove Front Wiper Assembly 2629
How to Install Front Wiper Assembly 2634
Electrical System 2643
Remove and Install Engine Controller Assembly 2643
How to Remove Engine Controller Assembly 2643
How to Install Engine Controller Assembly 2645
Remove and Install Pump Controller Assembly 2646
How to Remove Pump Controller Assembly 2646
How to Install Pump Controller Assembly 2650
Remove and Install KomVision Controller Assembly 2655
How to Remove KomVision Controller Assembly 2655
How to Install KomVision Controller Assembly 2656
Remove and Install Machine Monitor Assembly 2658
How to Remove Machine Monitor Assembly 2658
How to Install Machine Monitor Assembly 2661
Remove and Install Pump Swash Plate Sensor 2665
How to Remove Pump Swash Plate Sensor 2665
How to Install Pump Swash Plate Sensor 2666
Remove and Install Mass Air Flow and Temperature Sensor 2667
How to Remove Mass Air Flow and Temperature Sensor 2667
How to Install Mass Air Flow and Temperature Sensor 2667
Remove and Install KCCV Crankcase Pressure Sensor 2669
How to Remove KCCV Crankcase Pressure Sensor 2669
How to Install KCCV Crankcase Pressure Sensor 2670
Remove and Install SCR Temperature Sensor 2671
How to Remove SCR Temperature Sensor 2671
How to Install SCR Temperature Sensor 2673
Remove and Install KomVision Camera 2676
How to Remove KomVision Camera 2676
How to Install KomVision Camera 2679
Remove and Install Gateway Function Controller Assembly 2682
How to Remove Gateway Function Controller Assembly 2682
How to Install Gateway Function Controller Assembly 2687
Remove and Install Communication Terminal Wiring Harness 2692
How to Remove Communication Terminal Wiring Harness 2692
How to Install Communication Terminal Wiring Harness 2700
Remove and Install Communication Terminal 2709
How to Remove Communication Terminal 2709
How to Install Communication Terminal 2711
60 Maintenance Standard 2715
Table of Contents 2716
Engine and Cooling System 2717
Maintenance Standard for Engine Mount 2717
Maintenance Standard for Cooling System 2718
Power Train 2719
Maintenance Standard for Swing Circle 2719
Maintenance Standard for Swing Machinery 2720
Maintenance Standard for Final Drive 2722
Maintenance Standard for Sprocket 2724
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2725
Undercarriage and Frame 2726
Maintenance Standard for Track Frame and Idler Cushion 2726
Maintenance Standard for Idler 2728
Maintenance Standard for Track Roller 2730
Maintenance Standard for Carrier Roller 2732
Maintenance Standard for Track Shoes 2733
Maintenance Standard for Triple Shoes 2736
Hydraulic System 2737
Maintenance Standard for Hydraulic Tank 2737
Maintenance Standard for Main Pump 2738
Maintenance Standard for LS-EPC Valve 2739
Maintenance Standard for PC-EPC Valve 2740
Maintenance Standard for Swing Motor 2741
Maintenance Standard for Travel Motor 2744
Maintenance Standard for Control Valve 2747
Maintenance Standard for Boom Anti-Drop Valve 2757
Maintenance Standard for Arm Anti-Drop Valve 2759
Maintenance Standard for Work Equipment and Swing PPC Valve 2761
Maintenance Standard for Travel PPC Valve 2764
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2767
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2768
Maintenance Standard for 2nd-Line Attachment PPC Valve 2770
Maintenance Standard for Solenoid Valve 2772
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 2773
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2774
Maintenance Standard for Center Swivel Joint 2775
Work Equipment 2776
Maintenance Standard for Work Equipment Linkage 2776
Dimensions of Arm 2781
Dimensions of Bucket 2783
Maintenance Standard for Boom Cylinder 2785
Maintenance Standard for Arm Cylinder 2786
Maintenance Standard for Bucket Cylinder 2787
80 Appendix 2789
Table of Contents 2790
Precautions Before Work 2792
Air Conditioner System 2793
Precautions for Refrigerant 2793
Air Conditioner Component 2794
Specifications of Air Conditioner 2796
Structure and Function of Refrigeration Cycle 2797
Outline of Refrigeration Cycle 2798
Component Parts of Air Conditioner System 2800
Air Conditioner Unit 2800
Configuration Diagram of Air Conditioner Unit 2800
Function of Air Conditioner Unit 2802
Component Parts of Air Conditioner Unit 2804
Function of Evaporator as Air Conditioner Unit Component 2805
Function of Heater Core as Air Conditioner Unit Component 2805
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2805
Function of Servo Motor as Air Conditioner Unit Component 2805
Structure of Expansion Valve as Air Conditioner Unit Component 2806
Function of Expansion Valve as Air Conditioner Unit Component 2806
Operate Expansion Valve as Air Conditioner Unit Component 2806
Function of Dual Pressure Switch 2807
Air Conditioner Controller 2808
Structure of Air Conditioner Controller 2808
Compressor 2809
Structure of Compressor 2809
Specifications of Compressor 2809
Function of Compressor 2809
Condenser 2810
Structure of Condenser 2810
Specifications of Condenser 2810
Function of Condenser 2810
Air Conditioner Related Sensors 2812
Structure of Sunlight Sensor 2812
Function of Sunlight Sensor 2812
Structure of Outside Temperature Sensor 2812
Function of Outside Air Temperature Sensor 2812
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2814
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2816
System Diagram of Air Conditioner 2818
Input and Output Signals of Air Conditioner Controller 2819
Function of Air Conditioner Controller 2820
Locations of Air Conditioner Parts and Layout of Connectors 2821
Examine Air Leakage (Duct) 2825
How to Examine Air Leakage (Duct) 2825
Examine Air Conditioner with Self-Diagnosis Function 2827
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2828
Examine Vent (Mode) Changeover 2829
How to Examine Vent (Mode) Changeover 2829
Examine Fresh/Recirc Air Changeover 2831
How to Examine Fresh/Recirc Air Changeover 2831
Examine Sunlight Sensor 2832
How to Examine Sunlight Sensor 2832
Examine Refrigerant (Dual) Pressure Switch 2833
How to Examine Refrigerant (Dual) Pressure Switch 2833
Examine Relay 2834
How to Examine Relay 2834
Air Conditioner Troubleshooting Chart 1 2835
Air Conditioner Troubleshooting Chart 2 2836
Information Shown in Troubleshooting Table 2839
Failure Code [879AKA] 2840
Failure Code [879AKB] 2841
Failure Code [879BKA] 2842
Failure Code [879BKB] 2844
Failure Code [879CKA] 2846
Failure Code [879CKB] 2847
Failure Code [879DKZ] 2848
Failure Code [879EMC] 2850
Failure Code [879FMC] 2851
Failure Code [879GKX] 2852
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2854
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2856
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2859
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2861
Troubleshooting by Gauge Pressure 2863
Connect Service Tool 2866
How to Connect Service Tool 2866
Precautions for Disconnection and Connection of Air Conditioner Piping 2868
Handle Compressor Oil 2870
How to Replace Desiccant 2872
90 Circuit Diagrams 2875
Table of Contents 2876
Hydraulic Circuit Diagram 2877
Symbols Used in Hydraulic Circuit Diagram 2877
Hydraulic Circuit Diagram (1/2) 2881
Hydraulic Circuit Diagram (2/2) 2883
Electrical Circuit Diagram 2885
Symbols Used in Electric Circuit Diagram 2885
Electrical Circuit Diagram (1/10) 2889
Electrical Circuit Diagram (2/10) 2891
Electrical Circuit Diagram (3/10) 2893
Electrical Circuit Diagram (4/10) 2895
Electrical Circuit Diagram (5/10) 2897
Electrical Circuit Diagram (6/10) 2899
Electrical Circuit Diagram (7/10) 2901
Electrical Circuit Diagram (8/10) 2903
Electrical Circuit Diagram (9/10) 2905
Electrical Circuit Diagram (10/10) 2907
Index 2909

S.V  21/12/24