Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-07 PDF

Description

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-07 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-07 – PDF DOWNLOAD 

Language : English
Pages : 3154
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-07 – PDF DOWNLOAD 

SERIAL NUMBERS 85001 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 PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-07 – PDF DOWNLOAD 

SERIAL NUMBERS 85001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 22
Foreword, Safety, Basic Information 25
How to Read the Shop Manual 25
Safety Notice for Operation 27
Precautions to Prevent Fire 35
Procedures If Fire Occurs 37
Precautions When You Discard Waste Materials 38
Procedures for Exhaust Gas Regulations 39
Precautions for DEF 40
General Character and Precautions for Handling 40
Precautions When You Add 40
Precautions for Storage 40
Precautions for Fire Hazard and Leakage 40
Other Precautions 40
Store DEF 41
Precautions When You Handle Hydraulic Equipment 42
Precautions When You Disconnect and Connect Pipings 45
Precautions When You Handle Electrical Equipment 52
Precautions When You Handle Fuel System Equipment 54
Precautions When You Handle Intake System Equipment 55
Practical Use of KOMTRAX 56
Disconnect and Connect Push-Pull Type Coupler 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 59
Precautions for Disconnection and Connection of Connectors 61
Disconnect and Connect Deutsch Connector 65
How to Disconnect and Connect Slide Lock Type Connector 66
Disconnect and Connect Connector with Lock to Pull 68
Disconnect and Connect Connector with Lock to Push 69
Disconnect and Connect Connector with Housing to Rotate 71
How to Read the Codes for Electric Cable 72
Explanation of Terms for Maintenance Standard 76
Standard Tightening Torque Table 79
Conversion Table 86
01 Specification 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC490LC-11 93
Working Range Drawings 95
Working Range: PC490LC-11 95
Specifications 96
Specifications: PC490LC-11 96
Weight Table 99
Weight Table: PC490LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 108
Layout Drawing of Urea SCR System (Applicable Machine: 85001 to 86052) 108
Layout Drawing of Urea SCR System (Applicable Machine: 86053 to 86205) 112
Layout Drawing of Urea SCR System (Applicable Machine: 86206 and up) 116
Urea SCR System Diagram 120
Function of Urea SCR System 121
Function of DEF System (Applicable Machine: 85001 to 86052) 121
Function of DEF System (Applicable Machine: 86053 and Up) 123
Inducement Strategy 125
Component Parts of Urea SCR System 139
DEF Mixing Tube 139
SCR Assembly 140
DEF Tank 144
DEF Pump 146
DEF Injector 148
DEF Hose 149
DEF Tank Heating Valve 150
Boot-up System 151
Layout Drawing of Boot-up System 151
System Operating Lamp System 153
System Diagram of System Operating Lamp System 153
Function of Operation Lamp System 153
Operation of System Operating Lamp System 153
Battery Disconnect Switch 154
Function of Battery Disconnect Switch 154
Engine System 155
Layout Drawing of Engine System (Applicable Machine: 85001 to 86205) 155
Specifications of Engine System (Applicable Machine: 85001 to 86205) 156
Function of Engine System (Applicable Machine: 85001 to 86205) 157
Layout Drawing of Engine System (Applicable Machine: 86206 and up) 158
Specifications of Engine System (Applicable Machine: 86206 and up) 159
Function of Engine System (Applicable Machine: 86206 and up) 160
Engine Control System 161
System Diagram of Engine Control 161
Operation of Engine Control System 162
Auto-Deceleration System 164
System Diagram of Auto-Deceleration System 164
Function of Auto-Deceleration System 164
Operation of Auto-Deceleration System 165
Engine Automatic Warm-up System 166
System Diagram of Engine Automatic Warm-up System 166
Function of Engine Automatic Warm-up System 167
Overheat Prevention System 168
Overheat Prevention System Diagram 168
Function of Overheat Prevention System 169
Turbocharger Protection System 171
System Diagram of Turbocharger Protection System 171
Function of Turbocharger Protection System 172
Automatic Idle Stop System 173
System Diagram of Automatic Idle Stop System 173
Function of Automatic Idle Stop System 173
Operation of Automatic Idle Stop System 173
Component Parts of Engine System 176
VGT 176
EGR System 179
EGR Valve 181
EGR Cooler 183
KCCV System 184
KCCV Ventilator 185
KDPF 187
Cooling System 193
Layout Drawing of Cooling System 193
Specifications of Cooling System 194
Fan Speed Control System of Hydraulic Fan 196
Fan Speed Control System Diagram of Hydraulic Fan 196
Function of Fan Speed Control System of Hydraulic Fan 197
Engine Output Control System of Hydraulic Fan 198
Engine Output Control System Diagram of Hydraulic Fan 198
Function of Engine Output Control System of Hydraulic Fan 199
Fan Reverse Rotation System of Hydraulic Fan 201
Fan Reverse Rotation System Diagram of Hydraulic Fan 201
Function of Fan Reverse Rotation System of Hydraulic Fan 201
Component Parts of Cooling System 202
Cooling Fan Pump 202
Cooling Fan Motor 209
Control System 216
Layout Drawing of Control System 216
Machine Monitor System 219
System Diagram of Machine Monitor System 219
Function of Machine Monitor System 220
KomVision Controller 221
Structure of KomVision Controller 221
Input and Output Signals of KomVision Controller 221
KomVision Camera 225
Structure of KomVision Camera 225
Input and Output Signals of KomVision Camera 225
KomVision System 226
Layout Drawing of KomVision System 226
System Diagram of KomVision System 228
Function of KomVision System 228
KOMTRAX System 230
System Diagram of KOMTRAX System 230
Function of KOMTRAX System 230
Component Parts of Control System 231
Machine Monitor 231
Gateway Function Controller 244
Communication Terminal 247
Pump Controller 249
Resistor for PC-EPC Valve 253
CAN Terminating Resistor 253
Engine Controller 255
Fuel Control Dial 261
Fuel Feed Pump 263
Fuel Feed Pump Switch 264
Hydraulic System 265
Layout Drawing of Hydraulic System 265
CLSS 267
Structure of CLSS 267
Operation of Unload Valve and LS Pressure 269
Pump Swash Plate Angle (Oil Flow) Control 270
Pressure Compensation Control 283
Engine and Pump Combined Control System 287
Engine and Pump Combined Control System Diagram 287
Function of Engine and Pump Combined Control System 289
Pump and Valve Control System 294
Pump and Valve Control System Diagram 294
Function of Pump and Valve Control System 295
Component Parts of Hydraulic System 297
Hydraulic Tank 297
Main Pump 299
Control Valve 325
Work Equipment System 388
Layout Drawing of Work Equipment System 388
Structure of Valve Control 393
One-Touch Power Maximizing System 394
System Diagram of One-Touch Power Maximizing System 394
Function of One-Touch Power Maximizing System 395
Machine Push-up System 396
Machine Push-up System Diagram 396
Function of Machine Push-up System 397
PPC Lock System 398
System Diagram of PPC Lock 398
Function of PPC Lock System 398
Work Equipment and Travel Automatic Lock System 399
System Diagram of Lock Lever Automatic Lock System 399
Function of Work Equipment and Travel Automatic Lock System 399
Operation of Lock Lever Automatic Lock System 400
Attachment Oil Flow Adjuster System 401
Attachment Oil Flow Adjuster System Diagram 401
Function of Attachment Oil Flow Adjuster System 402
Tool Control System 403
Tool Control System Diagram 403
Function of Tool Control System 404
Component Parts of Work Equipment System 405
Work Equipment and Swing PPC Valve 405
1st-Line Attachment PPC Valve (with EPC Valve) 411
Solenoid Valve 416
Boom Anti-drop Valve 418
Arm Anti-Drop Valve 422
Attachment Circuit Selector Valve (For High Pressure) 426
Attachment Circuit Selector Valve (For Low Pressure) 428
1st-Line Attachment Variable Relief Valve 431
Attachment Bypass Solenoid Valve 434
Pilot Circuit Accumulator 435
Swing System 436
Layout Drawing of Swing System 436
Swing Control System Diagram 442
Function of Swing Control System 442
Component Parts of Swing System 446
Swing Motor 446
Swing Machinery 457
Swing Circle 459
Travel System 461
Layout Drawing of Travel System 461
System Diagram of Travel Control System 465
Function of Travel Control System 466
Component Parts of Travel System 467
Travel Motor 467
Final Drive 480
Travel PPC Valve 481
Center Swivel Joint 486
Undercarriage and Frame 488
Layout Drawing of Undercarriage 488
Specifications of Undercarriage 488
Work Equipment 489
Structure of Work Equipment 489
Function of Work Equipment 490
Work Equipment Clearance Adjustment Shim 491
Function of Work Equipment Clearance Adjustment Shim 491
Bucket Clearance Adjustment Shim 492
Function of Bucket Clearance Adjustment Shim 492
CAB Related Parts 493
ROPS CAB 493
Structure of ROPS CAB 493
Function of ROPS CAB 493
CAB Mount 494
Structure of CAB Mount 494
Function of CAB Mount 494
CAB Tipping Stopper 495
Structure of CAB Tipping Stopper 495
Function of CAB Tipping Stopper 495
20 Standard Value Table 497
Table of Contents 498
Standard Value Table for Engine 499
Standard Value Table for Engine: PC490LC-11 499
Standard Value Table for Machine 502
Standard Value Table for Machine: PC490LC-11 502
Machine Posture and Procedures to Measure Performance 518
30 Testing and Adjusting 523
Table of Contents 524
Precautions Before Work 527
Related Information on Testing and Adjusting 528
Tools for Testing and Adjusting 528
Sketch of Tools for Testing and Adjusting 536
Engine and Cooling System 538
Examine Engine Speed 538
How to Examine Engine Speed 538
Examine Boost Pressure 541
How to Examine Boost Pressure on Machine Monitor 541
How to Examine Boost Pressure by Testing Tool 542
Examine Exhaust Gas Color 543
How to Examine Exhaust Gas Color with the Handy Smoke Checker 543
How to Examine Exhaust Gas Color with Smoke Meter 544
Examine Mass Air Flow and Temperature Sensor 545
How to Examine Mass Air Flow and Temperature Sensor 545
Examine and Adjust Valve Clearance 547
Check Valve Clearance 547
Adjust Valve Clearance 550
Examine Compression Pressure 551
How to Examine Compression Pressure 551
Examine Blowby Pressure 554
How to Examine Blowby Pressure 554
Examine Engine Oil Pressure 556
Examine Engine Oil Pressure on Machine Monitor 556
Examine Engine Oil Pressure by Testing Tool 556
Examine EGR Valve and VGT Oil Pressure 558
How to Examine EGR Valve and VGT Oil Pressure 558
Examine Fuel Pressure 560
How to Examine Fuel Pressure 560
Examine Fuel Return Rate and Leakage 562
How to Examine Fuel Return Rate and Leakage 562
Bleed Air from Fuel System 565
How to Bleed Air from Fuel System 565
Examine Fuel Circuit for Leakage 567
How to Examine Fuel System for Leakage 567
Handle Cylinder Cut-out Mode Operation 569
Handle No-Injection Cranking Operation 570
Examine and Adjust Air Conditioner Compressor Belt Tension 571
How to Examine Air Conditioner Compressor Belt Tension 571
How to Adjust Air Conditioner Compressor Belt Tension 571
Clean Fuel Doser 573
How to Clean Fuel Doser 573
Write Injector Compensation Value to Engine Controller 575
Write Injector Compensation Value 575
Write Correction for Ash in Soot Accumulation to Engine Controller 581
How to Write Correction for Ash in Soot Accumulation to Engine Controller 581
Examine SCR Related Functions 582
Examine DEF Pump Raised Pressure 585
Examine Injection Volume from DEF Injector 588
Examine DEF Line Heater Relay 1 592
Examine DEF Line Heater Relay 2 594
Examine DEF Pump Heater Relay 597
Examine DEF Tank Heater Valve 600
Examine SCR Denitration Efficiency 603
Clean DEF Tank 607
How to Clean DEF Tank 607
Clean DEF Pump 611
How to Clean DEF Pump 611
Power Train 618
Examine Swing Circle Bearing Clearance 618
How to Examine Swing Circle Bearing Clearance 618
Undercarriage and Frame 619
Examine and Adjust Track Tension 619
How to Examine Track Tension 619
How to Adjust Track Tension 619
Hydraulic System 621
Release Remained Pressure in Hydraulic Circuit 621
How to Release Remained Pressure in Hydraulic System 621
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 624
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 625
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 631
Examine Oil Pressure of Control Circuit 635
Examine Oil Pressure in Control Circuit 635
Examine and adjust oil pressure in pump PC control circuit 637
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 637
Examine PC-EPC Valve Outlet Pressure 638
How to Adjust Oil Pressure in Pump PC Control Circuit 639
Examine and Adjust Oil Pressure in Pump LS Control Circuit 641
Examine LS Differential Pressure with Machine Monitor 641
Examine LS Differential Pressure by Testing Tool 642
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 643
How to Examine LS-EPC Valve Outlet Pressure 644
Adjust LS Valve 645
Examine Outlet Pressure of Solenoid Valve 646
How to Examine Outlet Pressure of Solenoid Valve 646
Operating Condition of Solenoid Valve 647
Examine PPC Valve Outlet Pressure 649
Examine Outlet Pressure in PPC Valve 649
Adjust Play of Work Equipment and Swing PPC Valves 651
How to Adjust Play of Work Equipment and Swing PPC Valves 651
Examine Pump Swash Plate Sensor 652
How to Examine pump swash plate sensor 652
Examine Cooling Fan Speed 653
How to Examine Cooling Fan Speed 653
Examine Oil Pressure in Fan Pump Circuit 654
How to Examine Oil Pressure in Fan Pump Circuit 654
Examine Fan Pump EPC Electric Current 656
How to Examine Fan Pump EPC Electric Current 656
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 657
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 657
Examine Parts Which Cause Hydraulic Drift of Work Equipment 659
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 659
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 659
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 660
Examine Oil Leakage 661
Examine Oil Leakage from Boom Cylinder 661
Examine Oil Leakage of Arm Cylinder 661
Examine Oil Leakage of Bucket Cylinder 662
How to Examine Oil Leakage of Swing Motor 662
How to Examine Oil Leakage of Travel Motor 663
Bleed Air from Hydraulic System 664
How to Bleed Air from Hydraulic System 666
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 669
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 669
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 673
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 673
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 677
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 677
CAB Related Parts 684
Examine CAB Tipping Stopper 684
How to Examine Cab Tipping Stopper 684
How to Adjust Mirrors 685
Procedure to Adjust Machine Left Front Mirror (A) 685
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 686
Procedure to Adjust Machine Right Front Mirror (B) 687
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 688
Procedure to Adjust Machine Right Side Mirror (C) 689
Electrical System 691
Set and Operate Machine Monitor 691
Operator Mode 694
Function to Show Technician Identification Status Screen 695
Function to Show Operator Identification Input Screen 695
Examine Function by LCD (Liquid Crystal Display) 696
Examine Function of Service Meter 696
Usage Limitation and Maintenance Password Change Function 696
Service Mode 699
Operate Service Mode 699
How to See Pre-defined Monitoring Information 701
How to Examine Self-Define Monitor Information 708
Abnormality Record Menu 719
How to See Maintenance Record 724
Maintenance Mode Setting 725
Set Phone Number Entry 729
Default Menu 730
Diagnostic Tests Menu 742
Adjustment Menu 752
No-Injection Cranking Operation 770
KOMTRAX Settings Menu 771
Show Service Message 773
Start Up KOMTRAX System 775
Adjust Rearview Camera Angle 780
How to Adjust Rearview Camera Angle 780
Adjust KomVision Camera Angle 783
How to Adjust KomVision Camera Angle 784
Adjust KomVision Related Function 788
Setting of KomVision (Main Setting) 788
Setting of KomVision (Camera Setting) 790
Setting of KomVision (Camera Calibration) 792
KomVision screen – Check 12 m visibility 805
Set Region of Bluetooth(R) Compatible Radio 808
Set Region of Bluetooth(R) Compatible Radio 808
Handle Voltage Circuit of Engine Controller 810
Handle Battery Disconnect Switch 811
Examine Diodes 812
Examine Diodes by Digital Tester 812
How to Examine Diodes by Analog Tester 812
Pm Clinic 813
Pm Clinic Service 813
Pm Clinic Check Sheet 814
40 Troubleshooting 829
Table of Contents 830
Precautions Before Work 841
Related Information to Troubleshooting 842
General Troubleshooting Points 842
Troubleshooting Points for Urea SCR System 843
Sequence of Events in Troubleshooting 857
Checks Before Troubleshooting 859
Inspection Procedure Before Troubleshooting 861
Walk-Around Check 861
Test in Accordance with Testing Procedure 863
Examine Fuel Level and Type 863
Examine for Impure Ingredient in Fuel 864
Examine Fuel Prefilter 864
Examine Water Separator, Drain Water and Sediment 864
Replace Fuel Prefilter Cartridge 865
Examine Fuel Main Filter 866
Examine Engine Oil Level (Oil Quantity in Oil Pan) 867
Examine Coolant Level (Reservoir Tank) 869
Examine Air Cleaner Clogging 869
Clean Outer Element 870
Replace Element 872
Examine Hydraulic Oil Level 873
Examine Hydraulic Oil Strainer 873
Examine Hydraulic Oil Filter 874
Examine Oil Level in Swing Machinery Case 875
Examine Oil Level in Damper Case 876
Examine Oil Level in Final Drive Case 876
Bleed Air from Fuel System 877
Bleed Air from Hydraulic System 877
How to Examine Electric Equipment 877
Preparation for Troubleshooting of Electrical System 883
Procedure for Troubleshooting 896
Symptom and Troubleshooting Numbers 899
Information Shown in Troubleshooting Table 903
Connector List and Layout 905
Connector Contact Connection Table 922
T-Branch Box and T-Branch Adapter Table 962
Fuse Location Table 968
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 970
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 974
Failure Code Table 976
Troubleshooting by Failure Code (Display of Code) 996
Failure Code [879AKA] 996
Failure Code [879AKB] 997
Failure Code [879BKA] 998
Failure Code [879BKB] 1000
Failure Code [879CKA] 1002
Failure Code [879CKB] 1003
Failure Code [879DKZ] 1004
Failure Code [879EMC] 1006
Failure Code [879FMC] 1007
Failure Code [879GKX] 1008
Failure Code [989L00] 1010
Failure Code [989M00] 1011
Failure Code [989N00] 1012
Failure Code [A1U0N3] 1013
Failure Code [A1U0N4] 1015
Failure Code [A900FR] 1017
Failure Code [A900N6] 1018
Failure Code [A900NY] 1019
Failure Code [AA10NX] 1020
Failure Code [AB00KE] 1022
Failure Code [AQ10N3] 1025
Failure Code [AS00N3] 1027
Failure Code [AS00R2] 1029
Failure Code [AS00R3] 1030
Failure Code [AS00R4] 1031
Failure Code [AS00R5] 1032
Failure Code [AS00R6] 1033
Failure Code [AS00ZK] 1034
Failure Code [AS10KM] 1035
Failure Code [AS10NR] 1036
Failure Code [AS10NT] 1037
Failure Code [B@BAZG] 1038
Failure Code [B@BAZK] 1039
Failure Code [B@BCNS] 1041
Failure Code [B@BCQA] 1042
Failure Code [B@BCZK] 1044
Failure Code [B@HANS] 1046
Failure Code [CA115] 1047
Failure Code [CA122] 1048
Failure Code [CA123] 1050
Failure Code [CA131] 1052
Failure Code [CA132] 1054
Failure Code [CA135] 1056
Failure Code [CA141] 1058
Failure Code [CA144] 1060
Failure Code [CA145] 1062
Failure Code [CA153] 1064
Failure Code [CA154] 1067
Failure Code [CA187] 1070
Failure Code [CA221] 1072
Failure Code [CA222] 1074
Failure Code [CA227] 1076
Failure Code [CA234] 1077
Failure Code [CA238] 1078
Failure Code [CA239] 1080
Failure Code [CA249] 1082
Failure Code [CA256] 1084
Failure Code [CA271] 1086
Failure Code [CA272] 1088
Failure Code [CA273] 1089
Failure Code [CA274] 1091
Failure Code [CA322] 1092
Failure Code [CA323] 1094
Failure Code [CA324] 1096
Failure Code [CA325] 1098
Failure Code [CA331] 1100
Failure Code [CA332] 1102
Failure Code [CA343] 1104
Failure Code [CA351] 1105
Failure Code [CA352] 1106
Failure Code [CA356] 1109
Failure Code [CA357] 1111
Failure Code [CA386] 1113
Failure Code [CA441] 1114
Failure Code [CA442] 1116
Failure Code [CA449] 1117
Failure Code [CA451] 1118
Failure Code [CA452] 1120
Failure Code [CA515] 1122
Failure Code [CA516] 1124
Failure Code [CA553] 1126
Failure Code [CA555] 1127
Failure Code [CA556] 1128
Failure Code [CA559] 1129
Failure Code [CA595] 1134
Failure Code [CA687] 1135
Failure Code [CA689] 1137
Failure Code [CA691] 1139
Failure Code [CA692] 1141
Failure Code [CA697] 1143
Failure Code [CA698] 1144
Failure Code [CA731] 1145
Failure Code [CA778] 1146
Failure Code [CA1117] 1149
Failure Code [CA1664] 1150
Failure Code [CA1669] 1153
Failure Code [CA1673] 1154
Failure Code [CA1677] 1155
Failure Code [CA1678] 1156
Failure Code [CA1682] 1157
Failure Code [CA1683] 1159
Failure Code [CA1684] 1161
Failure Code [CA1686] 1163
Failure Code [CA1691] 1164
Failure Code [CA1694] 1167
Failure Code [CA1695] 1169
Failure Code [CA1696] 1170
Failure Code [CA1712] 1172
Failure Code [CA1713] 1175
Failure Code [CA1714] 1177
Failure Code [CA1715] 1178
Failure Code [CA1776] 1179
Failure Code [CA1777] 1182
Failure Code [CA1843] 1185
Failure Code [CA1844] 1187
Failure Code [CA1879] 1190
Failure Code [CA1881] 1193
Failure Code [CA1883] 1195
Failure Code [CA1885] 1198
Failure Code [CA1887] 1200
Failure Code [CA1921] 1202
Failure Code [CA1922] 1205
Failure Code [CA1923] 1210
Failure Code [CA1924] 1212
Failure Code [CA1925] 1214
Failure Code [CA1927] 1216
Failure Code [CA1928] 1218
Failure Code [CA1942] 1220
Failure Code [CA1963] 1221
Failure Code [CA1977] 1224
Failure Code [CA1993] 1227
Failure Code [CA2185] 1230
Failure Code [CA2186] 1232
Failure Code [CA2249] 1234
Failure Code [CA2265] 1235
Failure Code [CA2266] 1237
Failure Code [CA2271] 1239
Failure Code [CA2272] 1241
Failure Code [CA2349] 1243
Failure Code [CA2353] 1245
Failure Code [CA2357] 1247
Failure Code [CA2381] 1248
Failure Code [CA2382] 1250
Failure Code [CA2383] 1252
Failure Code [CA2386] 1254
Failure Code [CA2387] 1256
Troubleshooting Flowchart 1260
Failure Code [CA2555] 1261
Failure Code [CA2556] 1264
Failure Code [CA2637] 1266
Failure Code [CA2639] 1268
Failure Code [CA2732] 1271
Failure Code [CA2733] 1273
Failure Code [CA2741] 1275
Failure Code [CA2765] 1276
Failure Code [CA2771] 1277
Failure Code [CA2777] 1283
Failure Code [CA2878] 1286
Failure Code [CA2881] 1289
Failure Code [CA2976] 1292
Failure Code [CA3133] 1294
Failure Code [CA3134] 1296
Failure Code [CA3135] 1298
Failure Code [CA3142] 1301
Failure Code [CA3143] 1302
Failure Code [CA3144] 1303
Failure Code [CA3146] 1305
Failure Code [CA3147] 1306
Failure Code [CA3148] 1307
Failure Code [CA3151] 1309
Failure Code [CA3165] 1315
Failure Code [CA3167] 1317
Failure Code [CA3229] 1320
Failure Code [CA3231] 1322
Failure Code [CA3232] 1324
Failure Code [CA3235] 1328
Failure Code [CA3239] 1330
Failure Code [CA3241] 1333
Failure Code [CA3242] 1336
Failure Code [CA3251] 1339
Failure Code [CA3253] 1341
Failure Code [CA3254] 1344
Failure Code [CA3255] 1347
Failure Code [CA3256] 1351
Failure Code [CA3311] 1353
Failure Code [CA3312] 1355
Failure Code [CA3313] 1358
Failure Code [CA3314] 1359
Failure Code [CA3315] 1360
Failure Code [CA3316] 1363
Failure Code [CA3317] 1364
Failure Code [CA3318] 1365
Failure Code [CA3319] 1367
Failure Code [CA3321] 1368
Failure Code [CA3322] 1370
Failure Code [CA3419] 1373
Failure Code [CA3421] 1375
Failure Code [CA3497] 1377
Failure Code [CA3498] 1378
Failure Code [CA3543] 1379
Failure Code [CA3545] 1386
Failure Code [CA3547] 1388
Failure Code [CA3558] 1389
Failure Code [CA3559] 1391
Failure Code [CA3562] 1393
Failure Code [CA3563] 1395
Failure Code [CA3567] 1398
Failure Code [CA3568] 1401
Failure Code [CA3571] 1405
Failure Code [CA3572] 1407
Failure Code [CA3574] 1409
Failure Code [CA3575] 1411
Failure Code [CA3577] 1413
Failure Code [CA3578] 1415
Failure Code [CA3582] 1417
Failure Code [CA3583] 1423
Failure Code [CA3596] 1425
Failure Code [CA3649] 1427
Failure Code [CA3681] 1429
Failure Code [CA3682] 1434
Failure Code [CA3713] 1440
Failure Code [CA3717] 1443
Failure Code [CA3718] 1444
Failure Code [CA3725] 1445
Failure Code [CA3748] 1448
Failure Code [CA3751] 1450
Failure Code [CA3755] 1452
Failure Code [CA3866] 1454
Failure Code [CA3867] 1458
Failure Code [CA3868] 1461
Failure Code [CA3899] 1465
Failure Code [CA3911] 1467
Failure Code [CA3912] 1471
Failure Code [CA3932] 1473
Failure Code [CA3933] 1475
Failure Code [CA3934] 1477
Failure Code [CA3935] 1480
Failure Code [CA3936] 1482
Failure Code [CA4151] 1484
Failure Code [CA4152] 1488
Failure Code [CA4155] 1492
Failure Code [CA4156] 1494
Failure Code [CA4157] 1497
Failure Code [CA4158] 1499
Failure Code [CA4159] 1500
Failure Code [CA4161] 1501
Failure Code [CA4162] 1504
Failure Code [CA4163] 1507
Failure Code [CA4164] 1509
Failure Code [CA4165] 1511
Failure Code [CA4166] 1513
Failure Code [CA4168] 1515
Failure Code [CA4169] 1518
Failure Code [CA4171] 1520
Failure Code [CA4249] 1523
Failure Code [CA4251] 1525
Failure Code [CA4259] 1527
Failure Code [CA4261] 1529
Failure Code [CA4277] 1532
Failure Code [CA4281] 1536
Failure Code [CA4459] 1539
Failure Code [CA4461] 1541
Failure Code [CA4658] 1544
Failure Code [CA4731] 1548
Failure Code [CA4732] 1549
Failure Code [CA4739] 1550
Failure Code [CA4768] 1551
Failure Code [CA4769] 1553
Failure Code [CA4842] 1556
Failure Code [CA4952] 1560
Failure Code [CA5115] 1562
Failure Code [CA5179] 1565
Failure Code [CA5181] 1567
Failure Code [CA5383] 1569
Failure Code [D110KB] 1571
Failure Code [D19JKZ] 1573
Failure Code [D811MC] 1576
Failure Code [D862KA] 1577
Failure Code [D8ALKA] 1579
Failure Code [D8ALKB] 1582
Failure Code [D8AQKR] 1584
Failure Code [D8G1KT] 1591
Failure Code [D8G6KT] 1592
Failure Code [DA20MC] 1593
Failure Code [DA22KK] 1594
Failure Code [DA25KP] 1597
Failure Code [DA29KQ] 1600
Failure Code [DA2LKA] 1602
Failure Code [DA2LKB] 1605
Failure Code [DA2QKR] 1607
Failure Code [DA2RKR] 1616
Failure Code [DAF0MB] 1617
Failure Code [DAF0MC] 1618
Failure Code [DAF8KB] 1619
Failure Code [DAF9KQ] 1621
Failure Code [DAFGMC] 1622
Failure Code [DAFLKA] 1623
Failure Code [DAFLKB] 1626
Failure Code [DAFQKR] 1628
Failure Code [DAZ9KQ] 1636
Failure Code [DAZQKR] 1637
Failure Code [DB2QKR] 1644
Failure Code [DB2RKR] 1652
Failure Code [DBP0KM] 1656
Failure Code [DBP0KT] 1657
Failure Code [DBP5KB] 1658
Failure Code [DBP5KY] 1661
Failure Code [DBPQKR] 1664
Failure Code [DDNRKA] 1672
Failure Code [DDNRKY] 1674
Failure Code [DDNS00] 1676
Failure Code [DGH2KA] 1678
Failure Code [DGH2KB] 1680
Failure Code [DHA4KA] 1682
Failure Code [DHAAMA] 1684
Failure Code [DHACMA] 1686
Failure Code [DHPAMA] 1688
Failure Code [DHPBMA] 1691
Failure Code [DHS3MA] 1694
Failure Code [DHS4MA] 1697
Failure Code [DHS8MA] 1700
Failure Code [DHS9MA] 1703
Failure Code [DHSAMA] 1706
Failure Code [DHSBMA] 1709
Failure Code [DHSCMA] 1712
Failure Code [DHSDMA] 1715
Failure Code [DHSFMA] 1718
Failure Code [DHSGMA] 1721
Failure Code [DHSHMA] 1724
Failure Code [DHSJMA] 1727
Failure Code [DHSVMA] 1730
Failure Code [DHZAMA] 1733
Failure Code [DHZCL8] 1737
Failure Code [DKR0MA] 1738
Failure Code [DKR1MA] 1741
Failure Code [DKULKA] 1744
Failure Code [DKULKB] 1746
Failure Code [DKULKY] 1748
Failure Code [DLM3KA] 1750
Failure Code [DLM3KB] 1752
Failure Code [DLM3MB] 1754
Failure Code [DR10KA] 1755
Failure Code [DR12KA] 1758
Failure Code [DR20KA] 1760
Failure Code [DR21KX] 1762
Failure Code [DR30KA] 1764
Failure Code [DR31KX] 1766
Failure Code [DR40KA] 1768
Failure Code [DUMBKA] 1770
Failure Code [DUMBKB] 1773
Failure Code [DV20KB] 1775
Failure Code [DW43KA] 1777
Failure Code [DW43KB] 1779
Failure Code [DW43KY] 1781
Failure Code [DW45KA] 1783
Failure Code [DW45KB] 1786
Failure Code [DW45KY] 1789
Failure Code [DW4CKY] 1791
Failure Code [DW7BKA] 1792
Failure Code [DW7BKB] 1794
Failure Code [DW7BKY] 1796
Failure Code [DW91KA] 1797
Failure Code [DW91KB] 1799
Failure Code [DW91KY] 1801
Failure Code [DWA2KA] 1803
Failure Code [DWA2KB] 1805
Failure Code [DWA2KY] 1807
Failure Code [DWK0KA] 1809
Failure Code [DWK0KB] 1811
Failure Code [DWK0KY] 1813
Failure Code [DWK2KA] 1815
Failure Code [DWK2KB] 1817
Failure Code [DWK2KY] 1819
Failure Code [DWK8KA] 1821
Failure Code [DWK8KB] 1823
Failure Code [DWK8KY] 1825
Failure Code [DWPUKA] 1827
Failure Code [DWPUKB] 1829
Failure Code [DWPUKY] 1831
Failure Code [DX16KA] 1833
Failure Code [DX16KB] 1835
Failure Code [DXA8KA] 1837
Failure Code [DXA8KB] 1839
Failure Code [DXA9KA] 1841
Failure Code [DXA9KB] 1843
Failure Code [DXE0KA] 1845
Failure Code [DXE0KB] 1847
Failure Code [DXE4KA] 1849
Failure Code [DXE4KB] 1851
Failure Code [DXE4KY] 1853
Failure Code [DXE5KA] 1855
Failure Code [DXE5KB] 1857
Failure Code [DXE6KA] 1859
Failure Code [DXE6KB] 1861
Failure Code [DXE7KA] 1863
Failure Code [DXE7KB] 1865
Failure Code [DXE7KY] 1867
Failure Code [DXE8KA] 1869
Failure Code [DXE8KB] 1871
Failure Code [DXE8KY] 1873
Failure Code [DXE9KA] 1875
Failure Code [DXE9KB] 1877
Failure Code [DXE9KY] 1879
Failure Code [DXEAKA] 1881
Failure Code [DXEAKB] 1883
Failure Code [DXEAKY] 1885
Failure Code [DXEKKA] 1887
Failure Code [DXEKKB] 1889
Failure Code [DXEKKY] 1891
Failure Code [DXELKA] 1893
Failure Code [DXELKB] 1895
Failure Code [DXELKY] 1897
Failure Code [DY20KA] 1899
Failure Code [DY20MA] 1901
Failure Code [DY2CKB] 1903
Failure Code [DY2DKB] 1906
Failure Code [DY2EKB] 1908
Failure Code [F311KA] 1910
Failure Code [F311KB] 1912
Failure Code [F312KA] 1914
Failure Code [F312KB] 1916
Failure Code [F313KA] 1918
Failure Code [F313KB] 1920
Failure Code [F314KA] 1923
Failure Code [F314KB] 1925
Failure Code [F315KB] 1927
Failure Code [F315KY] 1929
Failure Code [F316KB] 1931
Failure Code [F316KY] 1933
Failure Code [F318KB] 1935
Failure Code [F318KY] 1938
Failure Code [F31AKB] 1940
Failure Code [F31AKY] 1942
Failure Code [F31BKB] 1944
Failure Code [F31BKY] 1946
Failure Code [F31CKB] 1948
Failure Code [F31CKY] 1950
Failure Code [F31DKB] 1952
Failure Code [F31DKY] 1954
Failure Code [F31EKB] 1956
Failure Code [F31EKY] 1958
Troubleshooting of Electrical System (E-Mode) 1960
E-1 Engine Does Not Start (Engine Does Not Crank) 1960
E-2 Manual Preheating System Does Not Operate 1966
E-3 Automatic Preheating System Does Not Operate 1969
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1971
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1973
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1976
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1977
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1978
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1979
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1980
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1981
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1982
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1983
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1984
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation 1985
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum 1986
E-17 Display of Fuel Gauge is Different from Actual Fuel Level 1988
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1989
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1990
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1991
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1993
E-22 Some Areas of Machine Monitor Screen are Not Shown 1994
E-23 Function Switch Does Not Operate 1995
E-24 Automatic Warm-up System Does Not Work (in Cold Weather) 1996
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1997
E-26 Auto-Decelerator is Not Operated or Canceled with Lever 1998
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1999
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 2000
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 2001
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 2002
E-31 Alarm Buzzer Cannot be Canceled 2004
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position 2005
E-33 Service Mode Cannot be Selected 2006
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 2007
E-35 All Work Equipment, Swing and Travel Do Not Lock 2009
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 2010
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 2013
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor 2015
E-39 One-Touch Power Maximizing Function is Not Cancelled 2017
E-40 Alarm Does Not Sound During Travel 2018
E-41 Alarm Does Not Stop When Machine Stops 2020
E-42 Horn Does Not Sound 2021
E-43 Horn Does Not Stop 2025
E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 2027
E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2028
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated 2030
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2031
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2032
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function 2033
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function 2034
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2035
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2036
E-53 “Swing” is Not Shown Correctly with Monitoring Function 2037
E-54 “Travel” is Not Shown Correctly with Monitoring Function 2038
E-55 Service is Not Shown Correctly with Monitoring Function 2039
E-56 Attachment Hydraulic Circuit Cannot be Changed 2041
E-57 KOMTRAX System Does Not Operate Correctly 2042
E-58 Machine Push-up Function Cannot be Canceled 2043
E-59 Machine Push-Up Function Does Not Operate 2045
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2046
Information Shown in Troubleshooting Table (H-Mode) 2046
System Chart of Hydraulic and Mechanical Systems 2047
Failure Mode and Cause Table 2049
H-1 All Work Equipment, Swing and Travel Do Not Work 2057
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2058
H-3 Fine Control Performance or Response is Unsatisfactory 2060
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2061
H-5 Engine Speed Drops Largely or Engine Stops 2062
H-6 Speed or Power of Boom is Low 2064
H-7 Arm Speed or Power is Low 2070
H-8 Bucket Speed or Power is Low 2075
H-9 Work Equipment Does Not Move in Single Operation 2078
H-10 Hydraulic Drift of Boom is Large 2079
H-11 Hydraulic Drift of Arm is Large 2081
H-12 Hydraulic Drift of Bucket is Large 2083
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2084
H-14 Time Lag of Work Equipment is Large 2085
H-15 One-Touch Power Maximizing Function Does Not Operate 2086
H-16 Machine Push-Up Function Does Not Operate 2087
H-17 Attachment Circuit Cannot be Changed 2088
H-18 Oil Flow in Attachment Circuit Cannot be Changed 2089
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2090
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely 2091
H-21 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 2092
H-22 Machine Does Not Travel Straight 2093
H-23 Machine is Not Steered Correctly or Steering Power is Low 2095
H-24 Travel Speed is Low 2098
H-25 One of Tracks Does Not Run 2100
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2101
H-27 Machine Does Not Swing to Right or Left 2102
H-28 Upper Structure Swings Only to Right or Left 2103
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 2104
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction 2105
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2106
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2107
H-33 Shock is Large When Upper Structure Stops Swing Operation 2108
H-34 There is Large Unusual Noise When It Stops Swing Operation 2109
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2110
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2111
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2112
H-38 Unusual Noise is Heard from Around Fan 2113
Troubleshooting of Engine (S-Mode) 2114
Information Shown in Troubleshooting Table (S-Mode) 2114
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2115
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2116
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2117
S-4 Engine Startability is Unsatisfactory 2118
S-5 Engine Does Not Pick Up Smoothly 2120
S-6 Engine Stops During Operation 2122
S-7 Engine Runs Rough or is Not Stable 2124
S-8 Engine Lacks Power 2125
S-9 KDPF Becomes Clogged in a Short Time 2127
S-10 Engine Oil Consumption is Excessive 2129
S-11 Oil Becomes Dirty Quickly 2130
S-1 Fuel Consumption is Excessive 2131
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2132
S-14 Oil Pressure Drops 2133
S-15 Fuel Mixes Into Engine Oil 2135
S-16 Water Mixes Into Engine Oil (Milky) 2136
S-17 Coolant Temperature Increases Too High (Overheating) 2137
S-18 Unusual Noise is Heard 2138
S-19 Vibration is Excessive 2139
S-2 Air Cannot be Bled from Fuel Circuit 2140
S-21 Active Regeneration is Done Frequently 2141
S-22 Active Regeneration Continues Long 2143
S-23 White Smoke is Exhausted During Active Regeneration 2144
S-24 DEF Consumption is Excessive 2145
S-25 There is Unusual Smell (Irritating Odor) 2147
S-26 Foreign Materials Enter DEF (DEF Increases) 2148
50 Disassembly and Assembly 2149
Table of Contents 2150
Precautions Before Work 2156
Related Information on Disassembly and Assembly 2157
How to Read This Manual 2157
Coating Materials List 2158
Special Tool List 2163
Sketches of Special Tools 2175
Engine and Cooling System 2181
Remove and Install Supply Pump Assembly 2181
Remove Supply Pump Assembly 2181
Install Supply Pump Assembly 2187
Remove and Install Injector Assembly 2196
How to Remove Injector Assembly 2196
How to Install Injector Assembly 2202
Remove and Install Fuel Doser Assembly 2212
How to Remove Fuel Doser 2212
How to Install Fuel Doser 2213
Remove and Install Cylinder Head Assembly 2215
How to Remove Cylinder Head Assembly 2216
How to Install Cylinder Head Assembly 2225
Remove and Install EGR Valve Assembly 2238
Remove EGR Valve Assembly 2238
Install EGR Valve Assembly 2240
Remove and Install EGR Cooler Assembly 2242
How to Remove EGR Cooler Assembly 2242
How to Install EGR Cooler Assembly 2246
Remove and Install Starter Assembly 2252
Remove Starting Motor Assembly 2252
Install Starting Motor Assembly 2253
Remove and Install Alternator Belt 2255
Remove Alternator Belt 2255
Install Alternator Belt 2258
Remove and Install Radiator Assembly 2263
How to Remove Radiator Assembly 2263
How to Install Radiator Assembly 2265
Remove and Install Cooling Fan and Fan Motor Assembly 2268
Remove Cooling Fan and Fan Motor Assembly 2268
Install Cooling Fan and Fan Motor Assembly 2272
Remove and Install Hydraulic Oil Cooler Assembly 2277
How to Remove Hydraulic Oil Cooler Assembly 2277
How to Install Hydraulic Oil Cooler Assembly 2279
Remove and Install Aftercooler Assembly 2281
Remove Aftercooler Assembly 2281
Install Aftercooler Assembly 2283
Remove and Install Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205) 2287
How to Remove Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205) 2288
How to Install Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205) 2306
Remove and Install Engine and Main Pump Assembly (Applicable Machine: 86206 and up) 2325
How to Remove Engine and Main Pump Assembly (Applicable Machine: 86206 and up) 2326
How to Install Engine and Main Pump Assembly (Applicable Machine: 86206 and up) 2344
Remove and Install Engine Front Oil Seal 2363
How to Remove Engine Front Oil Seal 2364
How to Install Engine Front Oil Seal 2366
Remove and Install Engine Rear Oil Seal 2370
How to Remove Engine Rear Oil Seal 2371
How to Install Engine Rear Oil Seal 2374
Remove and Install Engine Hood Assembly 2380
How to Remove Engine Hood Assembly 2380
How to Install Engine Hood Assembly 2388
Remove and Install Fuel Tank Assembly 2399
Remove Fuel Tank Assembly 2399
Install Fuel Tank Assembly 2403
Remove and Install DEF Tank Assembly 2407
How to Remove DEF Tank Assembly 2407
How to Install DEF Tank Assembly 2413
Remove and Install DEF Tank Sensor Flange Assembly 2418
How to Remove DEF Tank Sensor Flange Assembly 2418
How to Install DEF Tank Sensor Flange Assembly 2425
Remove and Install DEF Tank Sensor 2431
Remove DEF Tank Sensor 2431
Install DEF Tank Sensor 2431
Remove and Install DEF Tank Filler Port Filter 2438
Remove DEF Tank Filler Port Filter 2438
Install DEF Tank Filler Port Filter 2440
Remove and Install KDPF Assembly (Applicable Machine: 85001 to 86205) 2443
How to Remove KDPF Assembly (Applicable Machine: 85001 to 86205) 2443
How to Install KDPF Assembly (Applicable Machine: 85001 to 86205) 2447
Remove and Install KDPF Assembly (Applicable Machine: 86206 and up) 2452
How to Remove KDPF Assembly (Applicable Machine: 86206 and up) 2452
How to Install KDPF Assembly (Applicable Machine: 86206 and up) 2456
Disassemble and Assemble of KDPF Assembly (Applicable Machine:85001 to 86205) 2460
How to Disassemble KDPF Assembly (Applicable Machine: 85001 to 86205) 2461
How to Assemble KDPF Assembly (Applicable Machine: 85001 to 86205) 2466
Disassemble and Assemble KDPF Assembly (Applicable Machine:86206 and up) 2473
How to Disassemble KDPF Assembly (Applicable Machine:86206 and up) 2474
How to Assemble KDPF Assembly (Applicable Machine: 86206 and up) 2476
Remove and Install SCR Assembly (Applicable Machine: 85001 to 86205) 2481
How to Remove SCR Assembly (Applicable Machine: 85001 to 86205) 2481
How to Install SCR Assembly (Applicable Machine: 85001 to 86205) 2484
Remove and Install SCR Assembly (Applicable Machine: 86206 and up) 2488
How to Remove SCR Assembly (Applicable Machine: 86206 and up) 2488
How to Install SCR Assembly (Applicable Machine: 86206 and up) 2491
Remove and Install KDPF and SCR Assembly (Applicable Machine: 85001 to 86205) 2495
How to Remove KDPF and SCR Assembly (Applicable Machine: 85001 to 86205) 2495
How to Install KDPF and SCR Assembly (Applicable Machine: 85001 to 86205) 2500
Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2505
How to Remove KDPF and SCR Assembly (Applicable Machine: 86206 and up) 2505
How to Install KDPF and SCR Assembly (Applicable Machine: 86206 and up) 2510
Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205) 2515
How to Remove KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205) 2515
Install KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205) 2520
Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2529
How to Remove KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2529
Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2534
Remove and Install Bellows Pipe Assembly 2543
How to Remove Bellows Pipe Assembly 2543
How to Install Bellows Pipe Assembly 2545
Remove and Install KCCV Assembly 2549
Remove KCCV Assembly 2549
Install KCCV Assembly 2550
Remove and Install DEF Mixing Tube 2554
Remove DEF Mixing Tube 2554
Install DEF Mixing Tube 2559
Remove and Install DEF Injector 2565
Remove DEF Injector 2565
Install DEF Injector 2569
Remove and Install DEF Pump 2574
How to Remove DEF Pump (Applicable Machine: 85001 to 86052) 2574
How to Install DEF Pump (Applicable Machine: 85001 to 86052) 2576
How to Remove DEF Pump (Applicable Machine: 86053 and up) 2577
How to Install DEF Pump (Applicable Machine: 86053 and up) 2579
Remove and Install DEF Hose 2581
How to Remove DEF Hose (Applicable Machine: 85001 to 86052) 2581
How to Install DEF Hose (Applicable Machine: 85001 to 86052) 2586
How to Remove DEF Hose (Applicable Machine: 86053 and up) 2594
How to Install DEF Hose (Applicable Machine: 86053 and up) 2599
Remove and Install Air Cleaner Assembly 2607
Remove Air Cleaner Assembly 2607
Install Air Cleaner Assembly 2608
Remove and Install Air Conditioner Compressor Assembly 2611
Remove Air Conditioner Compressor Assembly 2611
How to Install Air Conditioner Compressor Assembly 2614
Remove and Install Air Conditioner Condenser Assembly 2618
How to Remove Air Conditioner Condenser Assembly 2618
How to Install Air Conditioner Condenser Assembly 2619
Power Train 2621
Remove and Install Travel Motor and Final Drive Assembly 2621
Remove Travel Motor and Final Drive Assembly 2621
Install Travel Motor and Final Drive Assembly 2622
Disassemble and Assemble Final Drive Assembly 2623
Disassemble Final Drive Assembly 2623
Assemble Final Drive Assembly 2628
Remove and Install Swing Motor and Swing Machinery Assembly 2634
Remove Swing Motor and Swing Machinery Assembly 2634
Install Swing Motor and Swing Machinery Assembly 2635
Disassemble and Assemble Swing Machinery Assembly 2637
Disassemble Swing Machinery Assembly 2637
Assemble Swing Machinery Assembly 2641
Remove and Install Swing Circle Assembly 2647
Remove Swing Circle Assembly 2647
Install Swing Circle Assembly 2647
Undercarriage and Frame 2649
Separate and Connect Track Assembly 2649
Separate Track Assembly 2649
Install Track Assembly 2651
Remove and Install Sprocket 2654
Remove Sprocket 2654
Install Sprocket 2654
Remove and Install Idler and Idler Cushion Assembly 2656
Remove Idler and Idler Cushion Assembly 2656
Install Idler and Idler Cushion Assembly 2657
Disassemble and Assemble Idler Assembly 2659
Disassemble Idler Assembly 2659
Assemble Idler Assembly 2661
Disassemble and Assemble Idler Cushion Assembly 2666
Disassemble Idler Cushion Assembly 2667
Assemble Idler Cushion Assembly 2669
Disassemble and Assemble Track Roller Assembly 2672
Disassemble Track Roller Assembly 2673
Assemble Track Roller Assembly 2674
Disassemble and Assemble Carrier Roller Assembly 2678
Disassemble Carrier Roller Assembly 2678
Assemble Carrier Roller Assembly 2680
Remove and Install Revolving Frame Assembly 2683
Remove Revolving Frame Assembly 2683
Install Revolving Frame Assembly 2685
Remove and Install Counterweight Assembly 2688
Remove Counterweight Assembly 2688
Install Counterweight Assembly 2689
Hydraulic System 2691
Remove and Install Center Swivel Joint Assembly 2691
Remove Center Swivel Joint Assembly 2691
Install Center Swivel Joint Assembly 2693
Disassemble and Assemble Center Swivel Joint Assembly 2695
Disassemble Center Swivel Joint Assembly 2696
Assemble Center Swivel Joint Assembly 2696
Remove and Install Hydraulic Tank Assembly 2698
Remove Hydraulic Tank Assembly 2698
How to Install Hydraulic Tank Assembly 2703
Remove and Install Main Pump Assembly 2709
Remove Main Pump Assembly 2709
Install Main Pump Assembly 2713
Remove and Install Control Valve Assembly 2719
How to Remove Control Valve Assembly 2719
How to Install Control Valve Assembly 2724
Disassemble and Assemble Control Valve Assembly 2730
Replace Pressure Compensation Valve Seal Ring 2731
Assemble Control Valve Assembly 2732
Remove and Install ATT Bypass Solenoid 2737
Remove ATT Bypass Solenoid 2737
Install ATT Bypass Solenoid 2740
Disassemble and Assemble Work Equipment PPC Valve Assembly 2742
Disassemble Work Equipment PPC Valve Assembly 2742
How to Assemble Work Equipment PPC Valve Assembly 2743
Disassemble and Assemble Travel PPC Valve Assembly 2745
Disassemble Travel PPC Valve Assembly 2745
How to Assemble Travel PPC Valve Assembly 2746
Work Equipment 2748
Remove and Install Work Equipment Assembly 2748
Remove Work Equipment Assembly 2749
Install Work Equipment Assembly 2752
Remove and Install Boom Anti-drop Valve Assembly 2756
Remove Boom Anti-drop Valve Assembly 2756
Install Boom Anti-drop Valve Assembly 2758
Remove and Install Arm Anti-Drop Valve Assembly 2759
Remove Arm Anti-Drop Valve Assembly 2759
Install Arm Anti-Drop Valve Assembly 2761
Disassemble and Assemble Anti-Drop Valve Assembly 2762
Disassemble Anti-Drop Valve Assembly 2762
Assemble Anti-Drop Valve Assembly 2762
Disassemble and Assemble Work Equipment Cylinder Assembly 2763
How to Disassemble Work Equipment Cylinder Assembly 2763
How to Assemble Work Equipment Cylinder Assembly 2766
CAB Related Parts 2770
Remove and Install Operator Cab Assembly 2770
How to Remove Operator Cab Assembly 2770
Install Operator CAB Assembly 2777
Remove and Install Operator Cab Glass (Adhered Glass) 2784
Remove Operator CAB Glass (Adhered Glass) 2786
Install Operator CAB Glass (Adhered Glass) 2786
Remove and Install Front Window Assembly 2796
Remove Front Window Assembly 2796
Install Front Window Assembly 2799
Remove and Install Floor Frame Assembly 2805
How to Remove Floor Frame Assembly 2805
How to Install Floor Frame Assembly 2812
Remove and Install Air Conditioner Unit Assembly 2820
Remove Air Conditioner Unit Assembly 2820
Install Air Conditioner Unit Assembly 2826
Remove and Install Operator Seat 2833
Remove Operator’s Seat 2833
Install Operator’s Seat 2835
How to Remove and Install Seat Belt 2838
How to Remove Seat Belt 2838
How to Install Seatbelt 2839
Remove and Install Work Equipment Control Lever Assembly 2840
How to Remove Work Equipment Control Lever Assembly 2840
How to Install Work Equipment Control Lever Assembly 2846
Remove and Install Front Wiper Assembly 2855
Remove Front Wiper Assembly 2855
Install Front Wiper Assembly 2860
Electrical System 2869
Remove and Install Engine Controller Assembly 2869
Remove Engine Controller Assembly 2869
Install Engine Controller Assembly 2870
Remove and Install Pump Controller Assembly 2872
Remove Pump Controller Assembly 2872
Install Pump Controller Assembly 2875
Remove and Install Machine Monitor Assembly 2880
Remove Machine Monitor Assembly 2880
Install Machine Monitor Assembly 2883
Remove and Install KomVision Controller Assembly 2887
Remove KomVision Controller Assembly 2887
Install KomVision Controller Assembly 2888
Remove and Install Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205 2889
How to Remove Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205) 2889
How to Install Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205) 2890
Remove and Install Pump Swash Plate Sensor (Applicable Machine: 86206 and up) 2891
How to Remove Pump Swash Plate Sensor (Applicable Machine: 86206 and up) 2891
How to Install Pump Swash Plate Sensor (Applicable Machine: 86206 and up) 2892
Remove and Install Mass Air Flow and Temperature Sensor 2893
How to Remove Mass Air Flow and Temperature Sensor 2893
How to Install Mass Air Flow and Temperature Sensor 2894
Remove and Install KCCV Crankcase Pressure Sensor 2896
How to Remove KCCV Crankcase Pressure Sensor 2896
How to Install KCCV Crankcase Pressure Sensor 2897
Remove and Install SCR Temperature Sensor (Applicable Machine:85001 to 86205) 2899
Remove SCR Temperature Sensor (Applicable Machine:85001 to 86205) 2899
Install SCR Temperature Sensor (Applicable Machine:85001 to 86205) 2901
Remove and Install SCR Temperature Sensor (Applicable Machine:86206 and up) 2903
How to Remove SCR Temperature Sensor (Applicable Machine:86206 and up) 2903
How to Install SCR Temperature Sensor (Applicable Machine:86206 and up) 2904
Remove and Install KomVision Camera 2906
Remove KomVision Camera 2906
Install KomVision Camera 2907
Remove and Install Gateway Function Controller Assembly 2909
Remove Gateway Function Controller Assembly 2909
How to Install Gateway Function Controller Assembly 2914
Remove and Install Communication Terminal Wiring Harness 2919
Remove Communication Terminal Wiring Harness 2919
Install Communication Terminal Wiring Harness 2927
Remove and Install Communication Terminal 2936
Remove Communication Terminal 2936
Install Communication Terminal 2938
60 Maintenance Standard 2941
Table of Contents 2942
Engine and Cooling System 2943
Maintenance Standard for Engine Mount 2943
Maintenance Standard for Cooling System 2944
Maintenance Standard for Cooling Fan Pump 2945
Maintenance Standard for Servo Valve 2946
Maintenance Standard for Cooling Fan Motor 2947
Power Train 2948
Maintenance Standard for Swing Circle 2948
Maintenance Standard for Swing Machinery 2949
Maintenance Standard for Final Drive 2951
Maintenance Standard for Sprocket 2953
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2954
Undercarriage and Frame 2955
Maintenance Standard for Track Frame and Idler Cushion 2955
Maintenance Standard for Idler 2957
Maintenance Standard for Track Roller 2959
Maintenance Standard for Carrier Roller 2961
Maintenance Standard for Track Shoes 2962
Maintenance Standard for Triple Shoes 2965
Hydraulic System 2966
Maintenance Standard for Main Pump 2966
Maintenance Standard for Swing Motor 2968
Maintenance Standard for Travel Motor 2971
Maintenance Standard for Control Valve 2974
Maintenance Standard for Boom Anti-Drop Valve 2985
Maintenance Standard for Arm Anti-Drop Valve 2987
Maintenance Standard for Work Equipment and Swing PPC Valve 2989
Maintenance Standard for Travel PPC Valve 2992
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2995
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2996
Maintenance Standard for Solenoid Valve 2998
Maintenance Standard for Attachment Circuit Selector Valve 2999
Maintenance Standard for Center Swivel Joint 3000
Work Equipment 3001
Maintenance Standard for Work Equipment Linkage 3001
Dimensions of Arm 3006
Dimensions of Bucket 3008
Maintenance Standard for Boom Cylinder 3010
Maintenance Standard for Arm Cylinder 3011
Maintenance Standard for Bucket Cylinder 3012
80 Appendix 3013
Table of Contents 3014
Precautions Before Work 3016
Air Conditioner System 3017
Precautions for Refrigerant 3017
Air Conditioner Component 3018
Specifications of Air Conditioner 3020
Structure and Function of Refrigeration Cycle 3021
Outline of Refrigeration Cycle 3022
Component Parts of Air Conditioner System 3024
Air Conditioner Unit 3024
Configuration Diagram of Air Conditioner Unit 3024
Function of Air Conditioner Unit 3026
Component Parts of Air Conditioner Unit 3028
Function of Evaporator as Air Conditioner Unit Component 3029
Function of Heater Core as Air Conditioner Unit Component 3029
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3029
Function of Servo Motor as Air Conditioner Unit Component 3029
Structure of Expansion Valve as Air Conditioner Unit Component 3030
Function of Expansion Valve as Air Conditioner Unit Component 3030
Operate Expansion Valve as Air Conditioner Unit Component 3030
Function of Dual Pressure Switch 3031
Air Conditioner Controller 3032
Structure of Air Conditioner Controller 3032
Compressor 3033
Structure of Compressor 3033
Specifications of Compressor 3033
Function of Compressor 3033
Condenser 3034
Structure of Condenser 3034
Specifications of Condenser 3034
Function of Condenser 3034
Receiver Drier 3035
Structure of Receiver Dryer 3035
Specifications of Receiver Dryer 3035
Function of Receiver Dryer 3035
Air Conditioner Related Sensors 3036
Structure of Sunlight Sensor 3036
Function of Sunlight Sensor 3036
Structure of Outside Temperature Sensor 3036
Function of Outside Air Temperature Sensor 3036
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3038
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3040
System Diagram of Air Conditioner 3042
Input and Output Signals of Air Conditioner Controller 3043
Function of Air Conditioner Controller 3044
Locations of Air Conditioner Parts and Layout of Connectors 3045
Examine Air Leakage (Duct) 3049
How to Examine Air Leakage (Duct) 3049
Examine Air Conditioner with Self-Diagnosis Function 3051
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3052
Examine Vent (Mode) Changeover 3053
How to Examine Vent (Mode) Changeover 3053
Examine Fresh/Recirc Air Changeover 3055
How to Examine Fresh/Recirc Air Changeover 3055
Examine Sunlight Sensor 3056
How to Examine Sunlight Sensor 3056
Examine Refrigerant (Dual) Pressure Switch 3057
How to Examine Refrigerant (Dual) Pressure Switch 3057
Examine Relay 3058
How to Examine Relay 3058
Air Conditioner Troubleshooting Chart 1 3059
Air Conditioner Troubleshooting Chart 2 3060
Information Shown in Troubleshooting Table 3063
Failure Code [879AKA] 3064
Failure Code [879AKB] 3065
Failure Code [879BKA] 3066
Failure Code [879BKB] 3068
Failure Code [879CKA] 3070
Failure Code [879CKB] 3071
Failure Code [879DKZ] 3072
Failure Code [879EMC] 3074
Failure Code [879FMC] 3075
Failure Code [879GKX] 3076
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3078
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3080
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3083
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3085
Troubleshooting by Gauge Pressure 3087
Connect Service Tool 3090
How to Connect Service Tool 3090
Precautions for Disconnection and Connection of Air Conditioner Piping 3092
Handle Compressor Oil 3094
90 Circuit Diagrams 3097
Table of Contents 3098
Hydraulic Circuit Diagram 3099
Symbols Used in Hydraulic Circuit Diagram 3099
Hydraulic Circuit Diagram (1/2) 3103
Hydraulic Circuit Diagram (2/2) 3105
Electrical Circuit Diagram 3107
Symbols Used in Electric Circuit Diagram 3107
Electrical Circuit Diagram (1/11) 3111
Electrical Circuit Diagram (2/11) 3113
Electrical Circuit Diagram (3/11) 3115
Electrical Circuit Diagram (4/11) 3117
Electrical Circuit Diagram (5/11) 3119
Electrical Circuit Diagram (6/11) 3121
Electrical Circuit Diagram (7/11) 3123
Electrical Circuit Diagram (8/11) 3125
Electrical Circuit Diagram (9/11) 3127
Electrical Circuit Diagram (10/11) 3129
Electrical Circuit Diagram (11/11) 3131
Index 3133

S.V  21/12/24