Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06811-08 PDF  

Description

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06811-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06811-08 – PDF DOWNLOAD 

Language : English
Pages : 3168
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06811-08 – PDF DOWNLOAD 

SERIAL NUMBERS 85416 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.

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

TABLE OF CONTENTS:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06811-08 – PDF DOWNLOAD 

SERIAL NUMBERS 85416 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 133
DEF Mixing Tube 133
SCR Assembly 133
DEF Tank 138
DEF Pump 140
DEF Injector 142
DEF Hose 143
DEF Tank Heating Valve 144
Boot-up System 145
Layout Drawing of Boot-up System 145
System Operating Lamp System 147
System Diagram of System Operating Lamp System 147
Function of Operation Lamp System 147
Battery Isolator 149
Function of Battery Isolator 149
Engine System 150
Layout Drawing of Engine System (Applicable Machine: 85001 to 86205) 150
Specifications of Engine System (Applicable Machine: 85001 to 86205) 151
Function of Engine System (Applicable Machine: 85001 to 86205) 152
Layout Drawing of Engine System (Applicable Machine: 86206 and up) 153
Specifications of Engine System (Applicable Machine: 86206 and up) 154
Function of Engine System (Applicable Machine: 86206 and up) 155
Engine Control System 156
System Diagram of Engine Control 156
Function of Engine Control System 157
Auto-Deceleration System 160
System Diagram of Auto-Deceleration System 160
Function of Auto-Deceleration System 160
Operation of Auto-Deceleration System 161
Engine Automatic Warm-up System 162
System Diagram of Engine Automatic Warm-up System 162
Function of Engine Automatic Warm-up System 163
Overheat Prevention System 164
Overheat Prevention System Diagram 164
Function of Overheat Prevention System 165
Turbocharger Protection System 167
System Diagram of Turbocharger Protection System 167
Function of Turbocharger Protection System 168
Automatic Idle Stop System 169
System Diagram of Automatic Idle Stop System 169
Function of Automatic Idle Stop System 169
Component Parts of Engine System 172
VGT 172
EGR System 175
EGR Valve 177
EGR Cooler 179
KCCV System 180
KCCV Ventilator 181
KDPF 183
Cooling System 189
Layout Drawing of Cooling System 189
Specifications of Cooling System 190
Fan Speed Control System of Hydraulic Fan 192
Fan Speed Control System Diagram of Hydraulic Fan 192
Function of Fan Speed Control System of Hydraulic Fan 193
Engine Output Control System of Hydraulic Fan 194
Engine Output Control System Diagram of Hydraulic Fan 194
Function of Engine Output Control System of Hydraulic Fan 195
Fan Reverse Rotation System of Hydraulic Fan 197
Fan Reverse Rotation System Diagram of Hydraulic Fan 197
Function of Fan Reverse Rotation System of Hydraulic Fan 197
Component Parts of Cooling System 198
Cooling Fan Pump 198
Cooling Fan Motor 205
Control System 212
Layout Drawing of Control System 212
Machine Monitor System 215
System Diagram of Machine Monitor System 215
KomVision System 216
Layout Drawing of KomVision System 216
System Diagram of KomVision System 218
Function of KomVision System 218
KOMTRAX System 220
System Diagram of KOMTRAX System 220
Function of KOMTRAX System 220
PPC Levers 221
LH PPC Lever 221
RH PPC Lever 222
Automatic Grease System 223
Outline of AUTO Grease System 223
Component Parts of Control System 235
Machine Monitor 235
KomVision Controller 247
KomVision Camera 251
Gateway Function Controller 252
Communication Terminal 255
Pump Controller 257
Resistor for PC-EPC Valve 261
CAN Terminating Resistor 262
PPC Oil Pressure Switch 262
Engine Controller 264
Fuel Control Dial 270
Fuel Feed Pump 272
Fuel Feed Pump Switch 273
Hydraulic System 274
Layout Drawing of Hydraulic System 274
CLSS 276
Structure of CLSS 276
Operation of Unload Valve and LS Pressure 278
Pump Swash Plate Angle (Oil Flow) Control 279
Pressure Compensation Control 295
Engine and Pump Combined Control System 299
Engine and Pump Combined Control System Diagram 299
Function of Engine and Pump Combined Control System 301
Pump and Valve Control System 306
Pump and Valve Control System Diagram 306
Function of Pump and Valve Control System 307
Component Parts of Hydraulic System 309
Hydraulic Tank 309
Main Pump 311
Pilot Oil Filter 337
Control Valve 337
Work Equipment System 401
Layout Drawing of Work Equipment System 401
Structure of Valve Control 406
One-Touch Power Maximizing System 407
System Diagram of One-Touch Power Maximizing System 407
Function of One-Touch Power Maximizing System 408
Machine Push-up System 409
Machine Push-up System Diagram 409
Function of Machine Push-up System 410
PPC Lock System 411
System Diagram of PPC Lock 411
Function of PPC Lock System 411
Work Equipment and Travel Automatic Lock System 412
System Diagram of Lock Lever Automatic Lock System 412
Function of Work Equipment and Travel Automatic Lock System 412
Operation of Lock Lever Automatic Lock System 413
Attachment Oil Flow Adjuster System 414
Attachment Oil Flow Adjuster System Diagram 414
Function of Attachment Oil Flow Adjuster System 415
Component Parts of Work Equipment System 416
Work Equipment and Swing PPC Valve 416
1st-Line Attachment PPC Valve (with EPC Valve) 422
Solenoid Valve 427
Boom Anti-drop Valve 429
Arm Anti-Drop Valve 433
Attachment Circuit Selector Valve 437
Pilot Circuit Accumulator 440
Swing System 441
Layout Drawing of Swing System 441
Swing Control System Diagram 447
Function of Swing Control System 447
Component Parts of Swing System 451
Swing Motor 451
Swing Machinery 462
Swing Circle 464
Travel System 466
Layout Drawing of Travel System 466
System Diagram of Travel Control System 470
Function of Travel Control System 471
Component Parts of Travel System 472
Travel Motor 472
Final Drive 485
Travel PPC Valve 486
Center Swivel Joint 491
Undercarriage and Frame 493
Layout Drawing of Undercarriage 493
Specifications of Undercarriage 493
Work Equipment 494
Structure of Work Equipment 494
Function of Work Equipment 495
Work Equipment Clearance Adjustment Shim 496
Function of Work Equipment Clearance Adjustment Shim 496
Bucket Clearance Adjustment Shim 497
Function of Bucket Clearance Adjustment Shim 497
CAB Related Parts 498
ROPS CAB 498
Structure of ROPS CAB 498
Function of ROPS CAB 498
CAB Mount 499
Structure of CAB Mount 499
Function of CAB Mount 499
CAB Tipping Stopper 500
Structure of CAB Tipping Stopper 500
Function of CAB Tipping Stopper 500
20 Standard Value Table 501
Table of Contents 502
Standard Value Table for Engine 503
Standard Value Table for Engine: PC490LC-11 503
Standard Value Table for Machine 506
Standard Value Table for Machine: PC490LC-11 506
Machine Posture and Procedures to Measure Performance 522
Standard Value Table for Electricity 526
Standard Value Table for Electricity 526
30 Testing and Adjusting 537
Table of Contents 538
Precautions Before Work 541
Related Information on Testing and Adjusting 542
Tools for Testing and Adjusting 542
Sketch of Tools for Testing and Adjusting 550
Engine and Cooling System 552
Examine Engine Speed 552
How to Examine Engine Speed 552
Examine Boost Pressure 555
How to Examine Boost Pressure on Machine Monitor 555
How to Examine Boost Pressure by Testing Tool 556
Examine Exhaust Gas Color 557
How to Examine Exhaust Gas Color with the Handy Smoke Checker 557
How to Examine Exhaust Gas Color with Smoke Meter 558
Examine Mass Air Flow and Temperature Sensor 559
How to Examine Mass Air Flow and Temperature Sensor 559
Examine and Adjust Valve Clearance 561
Check Valve Clearance 561
Adjust Valve Clearance 563
Examine Compression Pressure 564
How to Examine Compression Pressure 564
Examine Blowby Pressure 567
How to Examine Blowby Pressure 567
Examine Engine Oil Pressure 569
Examine Engine Oil Pressure on Machine Monitor 569
Examine Engine Oil Pressure by Testing Tool 569
Examine EGR Valve and VGT Oil Pressure 571
How to Examine EGR Valve and VGT Oil Pressure 571
Examine Fuel Pressure 573
How to Examine Fuel Pressure 573
Examine Fuel Return Rate and Leakage 575
How to Examine Fuel Return Rate and Leakage 575
Bleed Air from Fuel System 578
How to Bleed Air from Fuel System 578
Examine Fuel Circuit for Leakage 580
How to Examine Fuel System for Leakage 580
Handle Cylinder Cut-out Mode Operation 582
Handle No-Injection Cranking Operation 583
Examine and Adjust Air Conditioner Compressor Belt Tension 584
How to Examine Air Conditioner Compressor Belt Tension 584
How to Adjust Air Conditioner Compressor Belt Tension 584
How to Replace Fan Belt 586
Clean Fuel Doser 587
How to Clean Fuel Doser 587
Write Injector Compensation Value to Engine Controller 589
Write Injector Compensation Value 589
Write Correction for Ash in Soot Accumulation to Engine Controller 595
How to Write Correction for Ash in Soot Accumulation to Engine Controller 595
Examine SCR Related Functions 596
Examine DEF Pump Raised Pressure 599
Examine Injection Volume from DEF Injector 602
Examine DEF Line Heater Relay 1 606
Examine DEF Line Heater Relay 2 608
Examine DEF Pump Heater Relay 611
Examine DEF Tank Heater Valve 614
Examine SCR Denitration Efficiency 617
Clean DEF Tank 622
How to Clean DEF Tank 622
Clean DEF Pump 626
How to Clean DEF Pump 626
Power Train 633
Examine Swing Circle Bearing Clearance 633
How to Examine Swing Circle Bearing Clearance 633
Undercarriage and Frame 634
Examine and Adjust Track Tension 634
How to Examine Track Tension 634
How to Adjust Track Tension 634
Hydraulic System 636
Release Remained Pressure in Hydraulic Circuit 636
How to Release Remained Pressure in Hydraulic System 636
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 641
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 642
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 648
Examine Oil Pressure of Control Circuit 652
Examine Oil Pressure in Control Circuit 652
Examine and adjust oil pressure in pump PC control circuit 654
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 654
Examine PC-EPC Valve Outlet Pressure 655
How to Adjust Oil Pressure in Pump PC Control Circuit 656
Examine and Adjust Oil Pressure in Pump LS Control Circuit 658
Examine LS Differential Pressure with Machine Monitor 658
Examine LS Differential Pressure by Testing Tool 659
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 660
How to Examine LS-EPC Valve Outlet Pressure 661
Adjust LS Valve 662
Examine Outlet Pressure of Solenoid Valve 663
How to Examine Outlet Pressure of Solenoid Valve 663
Operating Condition of Solenoid Valve 664
Examine PPC Valve Outlet Pressure 666
Examine Outlet Pressure in PPC Valve 666
Adjust Play of Work Equipment and Swing PPC Valves 668
How to Adjust Play of Work Equipment and Swing PPC Valves 668
Measure and Adjust Quick Coupler Control Valve Output Pressure 669
Examine Pump Swash Plate Sensor 671
How to Examine pump swash plate sensor 671
Examine Cooling Fan Speed 672
How to Examine Cooling Fan Speed 672
Examine Oil Pressure in Fan Pump Circuit 673
How to Examine Oil Pressure in Fan Pump Circuit 673
Examine Fan Pump EPC Electric Current 675
How to Examine Fan Pump EPC Electric Current 675
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 676
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 676
Examine Parts Which Cause Hydraulic Drift of Work Equipment 678
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 678
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 678
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 679
Examine Oil Leakage 680
Examine Oil Leakage from Boom Cylinder 680
Examine Oil Leakage of Arm Cylinder 680
Examine Oil Leakage of Bucket Cylinder 681
How to Examine Oil Leakage of Swing Motor 681
How to Examine Oil Leakage of Travel Motor 682
Bleed Air from Hydraulic System 683
How to Bleed Air from Hydraulic System 685
CAB Related Parts 688
Examine CAB Tipping Stopper 688
How to Examine Cab Tipping Stopper 688
How to Adjust Mirrors 689
Procedure to Adjust Machine Left Front Mirror (A) 689
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 690
Procedure to Adjust Machine Right Front Mirror (B) 691
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 692
Procedure to Adjust Machine Right Side Mirror (C) 693
Electrical System 695
Set and Operate Machine Monitor 695
Operator Mode 698
Function to Show Technician Identification Status Screen 699
Function to Show Operator Identification Input Screen 699
Examine Function by LCD (Liquid Crystal Display) 700
Examine Function of Service Meter 700
Usage Limitation and Maintenance Password Change Function 700
Service Mode 703
How to Operate Service Mode 703
How to See Pre-defined Monitoring Information 705
How to Examine Self-Define Monitor Information 712
Abnormality Record Menu 723
How to See Maintenance Record 728
Maintenance Mode Setting 729
Set Phone Number Entry 733
Default Menu 734
Diagnostic Tests Menu 742
Adjustment Menu 751
No-Injection Cranking Operation 773
KOMTRAX Settings Menu 774
Show Service Message 776
Start Up KOMTRAX System 778
Adjust Rearview Camera Angle 783
How to Adjust Rearview Camera Angle 783
Adjust KomVision Camera Angle 785
How to Adjust KomVision Camera Angle 786
Adjust KomVision Related Function 790
Setting of KomVision (Main Setting) 790
Setting of KomVision (Camera Setting) 792
Setting of KomVision (Camera Calibration) 794
KomVision screen – Check 12 m visibility 807
Set Region of Bluetooth(R) Compatible Radio 810
Set Region of Bluetooth(R) Compatible Radio 810
Handle Voltage Circuit of Engine Controller 812
Handle Battery Isolator Switch 813
Examine Diodes 814
Examine Diodes by Digital Tester 814
How to Examine Diodes by Analog Tester 814
Pm Clinic 815
Pm Clinic Service 815
Pm Clinic Check Sheet 819
40 Troubleshooting 833
Table of Contents 834
Precautions Before Work 845
Related Information to Troubleshooting 846
General Troubleshooting Points 846
Troubleshooting Points for Urea SCR System 847
Sequence of Events in Troubleshooting 861
Checks Before Troubleshooting 863
Inspection Procedure Before Troubleshooting 865
Walk-Around Check 865
Test in Accordance with Testing Procedure 867
Examine Fuel Level and Type 867
Examine for Impure Ingredient in Fuel 868
Examine Fuel Prefilter 868
Examine Water Separator, Drain Water and Sediment 868
Replace Fuel Prefilter Cartridge 869
Examine Fuel Main Filter 870
Examine Engine Oil Level (Oil Quantity in Oil Pan) 871
Examine Coolant Level (Reservoir Tank) 873
Examine Air Cleaner Clogging 873
Clean Outer Element 874
Replace Element 876
Examine Hydraulic Oil Level 877
Examine Hydraulic Oil Strainer 877
Examine Hydraulic Oil Filter 878
Examine Oil Level in Swing Machinery Case 879
Examine Oil Level in Damper Case 880
Examine Oil Level in Final Drive Case 880
Bleed Air from Fuel System 881
Bleed Air from Hydraulic System 881
How to Examine Electric Equipment 881
Automatic Grease System 887
Find Malfunctions 887
Malfunction Finding Procedures 889
Preparation for Troubleshooting of Electrical System 891
Procedure for Troubleshooting 904
Symptom and Troubleshooting Numbers 907
Information Shown in Troubleshooting Table 911
Connector List and Layout 913
Connector Contact Connection Table 927
T-Branch Box and T-Branch Adapter Table 967
Fuse Location Table 973
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 976
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 980
Failure Code Table 982
Troubleshooting by Failure Code (Display of Code) 1002
Failure Code [6AZ0ZG] 1002
Failure Code [879AKA] 1004
Failure Code [879AKB] 1005
Failure Code [879BKA] 1006
Failure Code [879BKB] 1008
Failure Code [879CKA] 1010
Failure Code [879CKB] 1011
Failure Code [879DKZ] 1012
Failure Code [879EMC] 1014
Failure Code [879FMC] 1015
Failure Code [879GKX] 1016
Failure Code [989L00] 1018
Failure Code [989M00] 1019
Failure Code [989N00] 1020
Failure Code [A1U0N3] 1021
Failure Code [A1U0N4] 1023
Failure Code [A900FR] 1025
Failure Code [A900N6] 1026
Failure Code [A900NY] 1027
Failure Code [AA10NX] 1028
Failure Code [AB00KE] 1030
Failure Code [AQ10N3] 1033
Failure Code [AS00N3] 1035
Failure Code [AS00R2] 1037
Failure Code [AS00R3] 1038
Failure Code [AS00R4] 1039
Failure Code [AS00R5] 1040
Failure Code [AS00R6] 1041
Failure Code [AS00ZK] 1042
Failure Code [AS10KM] 1043
Failure Code [AS10NR] 1044
Failure Code [AS10NT] 1045
Failure Code [B@BAZG] 1046
Failure Code [B@BAZK] 1047
Failure Code [B@BCNS] 1049
Failure Code [B@BCQA] 1050
Failure Code [B@BCZK] 1052
Failure Code [B@HANS] 1054
Failure Code [CA115] 1055
Failure Code [CA122] 1056
Failure Code [CA123] 1058
Failure Code [CA131] 1060
Failure Code [CA132] 1062
Failure Code [CA135] 1064
Failure Code [CA141] 1066
Failure Code [CA144] 1068
Failure Code [CA145] 1070
Failure Code [CA153] 1072
Failure Code [CA154] 1075
Failure Code [CA187] 1078
Failure Code [CA221] 1080
Failure Code [CA222] 1082
Failure Code [CA227] 1084
Failure Code [CA234] 1085
Failure Code [CA238] 1086
Failure Code [CA239] 1088
Failure Code [CA249] 1090
Failure Code [CA256] 1092
Failure Code [CA271] 1094
Failure Code [CA272] 1096
Failure Code [CA273] 1097
Failure Code [CA274] 1099
Failure Code [CA322] 1100
Failure Code [CA323] 1102
Failure Code [CA324] 1104
Failure Code [CA325] 1106
Failure Code [CA331] 1108
Failure Code [CA332] 1110
Failure Code [CA343] 1112
Failure Code [CA351] 1113
Failure Code [CA352] 1114
Failure Code [CA356] 1117
Failure Code [CA357] 1119
Failure Code [CA386] 1121
Failure Code [CA441] 1122
Failure Code [CA442] 1124
Failure Code [CA449] 1125
Failure Code [CA451] 1126
Failure Code [CA452] 1128
Failure Code [CA515] 1130
Failure Code [CA516] 1132
Failure Code [CA553] 1134
Failure Code [CA555] 1135
Failure Code [CA556] 1136
Failure Code [CA559] 1137
Failure Code [CA595] 1142
Failure Code [CA687] 1143
Failure Code [CA689] 1145
Failure Code [CA691] 1147
Failure Code [CA692] 1149
Failure Code [CA697] 1151
Failure Code [CA698] 1152
Failure Code [CA731] 1153
Failure Code [CA778] 1154
Failure Code [CA1117] 1157
Failure Code [CA1664] 1158
Failure Code [CA1669] 1161
Failure Code [CA1673] 1162
Failure Code [CA1677] 1163
Failure Code [CA1678] 1164
Failure Code [CA1682] 1165
Failure Code [CA1683] 1167
Failure Code [CA1684] 1169
Failure Code [CA1686] 1171
Failure Code [CA1691] 1172
Failure Code [CA1694] 1175
Failure Code [CA1695] 1177
Failure Code [CA1696] 1178
Failure Code [CA1712] 1180
Failure Code [CA1713] 1183
Failure Code [CA1714] 1185
Failure Code [CA1715] 1186
Failure Code [CA1776] 1187
Failure Code [CA1777] 1190
Failure Code [CA1843] 1193
Failure Code [CA1844] 1195
Failure Code [CA1879] 1198
Failure Code [CA1881] 1201
Failure Code [CA1883] 1203
Failure Code [CA1885] 1206
Failure Code [CA1887] 1208
Failure Code [CA1921] 1210
Failure Code [CA1922] 1213
Failure Code [CA1923] 1218
Failure Code [CA1924] 1220
Failure Code [CA1925] 1222
Failure Code [CA1927] 1224
Failure Code [CA1928] 1226
Failure Code [CA1942] 1228
Failure Code [CA1963] 1229
Failure Code [CA1977] 1232
Failure Code [CA1993] 1235
Failure Code [CA2185] 1238
Failure Code [CA2186] 1240
Failure Code [CA2249] 1242
Failure Code [CA2265] 1243
Failure Code [CA2266] 1245
Failure Code [CA2271] 1247
Failure Code [CA2272] 1249
Failure Code [CA2349] 1251
Failure Code [CA2353] 1253
Failure Code [CA2357] 1255
Failure Code [CA2381] 1256
Failure Code [CA2382] 1258
Failure Code [CA2383] 1260
Failure Code [CA2386] 1262
Failure Code [CA2387] 1264
Troubleshooting Flowchart 1268
Failure Code [CA2555] 1269
Failure Code [CA2556] 1272
Failure Code [CA2637] 1274
Failure Code [CA2639] 1276
Failure Code [CA2732] 1279
Failure Code [CA2733] 1281
Failure Code [CA2741] 1283
Failure Code [CA2765] 1284
Failure Code [CA2771] 1285
Failure Code [CA2777] 1291
Failure Code [CA2878] 1294
Failure Code [CA2881] 1297
Failure Code [CA2976] 1300
Failure Code [CA3133] 1302
Failure Code [CA3134] 1304
Failure Code [CA3135] 1306
Failure Code [CA3142] 1309
Failure Code [CA3143] 1310
Failure Code [CA3144] 1311
Failure Code [CA3146] 1313
Failure Code [CA3147] 1314
Failure Code [CA3148] 1315
Failure Code [CA3151] 1317
Failure Code [CA3165] 1323
Failure Code [CA3167] 1325
Failure Code [CA3229] 1328
Failure Code [CA3231] 1330
Failure Code [CA3232] 1332
Failure Code [CA3235] 1336
Failure Code [CA3239] 1338
Failure Code [CA3241] 1341
Failure Code [CA3242] 1344
Failure Code [CA3251] 1347
Failure Code [CA3253] 1349
Failure Code [CA3254] 1352
Failure Code [CA3255] 1355
Failure Code [CA3256] 1359
Failure Code [CA3311] 1361
Failure Code [CA3312] 1363
Failure Code [CA3313] 1366
Failure Code [CA3314] 1367
Failure Code [CA3315] 1368
Failure Code [CA3316] 1371
Failure Code [CA3317] 1372
Failure Code [CA3318] 1373
Failure Code [CA3319] 1375
Failure Code [CA3321] 1376
Failure Code [CA3322] 1378
Failure Code [CA3419] 1381
Failure Code [CA3421] 1383
Failure Code [CA3497] 1385
Failure Code [CA3498] 1386
Failure Code [CA3543] 1387
Failure Code [CA3545] 1394
Failure Code [CA3547] 1396
Failure Code [CA3558] 1397
Failure Code [CA3559] 1399
Failure Code [CA3562] 1401
Failure Code [CA3563] 1403
Failure Code [CA3567] 1406
Failure Code [CA3568] 1409
Failure Code [CA3571] 1413
Failure Code [CA3572] 1415
Failure Code [CA3574] 1417
Failure Code [CA3575] 1419
Failure Code [CA3577] 1421
Failure Code [CA3578] 1423
Failure Code [CA3582] 1425
Failure Code [CA3583] 1431
Failure Code [CA3596] 1433
Failure Code [CA3649] 1435
Failure Code [CA3681] 1437
Failure Code [CA3682] 1442
Failure Code [CA3713] 1448
Failure Code [CA3717] 1451
Failure Code [CA3718] 1452
Failure Code [CA3725] 1453
Failure Code [CA3748] 1456
Failure Code [CA3751] 1458
Failure Code [CA3755] 1460
Failure Code [CA3866] 1462
Failure Code [CA3867] 1466
Failure Code [CA3868] 1469
Failure Code [CA3899] 1473
Failure Code [CA3911] 1475
Failure Code [CA3912] 1479
Failure Code [CA3932] 1481
Failure Code [CA3933] 1483
Failure Code [CA3934] 1485
Failure Code [CA3935] 1488
Failure Code [CA3936] 1490
Failure Code [CA4151] 1492
Failure Code [CA4152] 1496
Failure Code [CA4155] 1500
Failure Code [CA4156] 1502
Failure Code [CA4157] 1505
Failure Code [CA4158] 1507
Failure Code [CA4159] 1508
Failure Code [CA4161] 1509
Failure Code [CA4162] 1512
Failure Code [CA4163] 1515
Failure Code [CA4164] 1517
Failure Code [CA4165] 1519
Failure Code [CA4166] 1521
Failure Code [CA4168] 1523
Failure Code [CA4169] 1526
Failure Code [CA4171] 1528
Failure Code [CA4249] 1531
Failure Code [CA4251] 1533
Failure Code [CA4259] 1535
Failure Code [CA4261] 1538
Failure Code [CA4277] 1541
Failure Code [CA4281] 1545
Failure Code [CA4459] 1548
Failure Code [CA4461] 1550
Failure Code [CA4658] 1553
Failure Code [CA4731] 1557
Failure Code [CA4732] 1558
Failure Code [CA4739] 1559
Failure Code [CA4768] 1560
Failure Code [CA4769] 1562
Failure Code [CA4842] 1565
Failure Code [CA4952] 1569
Failure Code [CA5115] 1571
Failure Code [CA5179] 1574
Failure Code [CA5181] 1576
Failure Code [CA5383] 1578
Failure Code [D110KB] 1580
Failure Code [D19JKZ] 1582
Failure Code [D811MC] 1585
Failure Code [D862KA] 1586
Failure Code [D8ALKA] 1588
Failure Code [D8ALKB] 1591
Failure Code [D8AQKR] 1593
Failure Code [D8G1KT] 1600
Failure Code [D8G6KT] 1601
Failure Code [DA20MC] 1602
Failure Code [DA22KK] 1603
Failure Code [DA25KP] 1606
Failure Code [DA29KQ] 1609
Failure Code [DA2LKA] 1611
Failure Code [DA2LKB] 1614
Failure Code [DA2QKR] 1616
Failure Code [DA2RKR] 1625
Failure Code [DAF0KM] 1626
Failure Code [DAF0MB] 1627
Failure Code [DAF0MC] 1628
Failure Code [DAF8KB] 1629
Failure Code [DAF9KQ] 1631
Failure Code [DAFGMC] 1632
Failure Code [DAFLKA] 1633
Failure Code [DAFLKB] 1636
Failure Code [DAFQKR] 1638
Failure Code [DAZ9KQ] 1646
Failure Code [DAZQKR] 1647
Failure Code [DB2QKR] 1654
Failure Code [DB2RKR] 1662
Failure Code [DBP0KM] 1666
Failure Code [DBP0KT] 1667
Failure Code [DBP5KB] 1668
Failure Code [DBP5KY] 1671
Failure Code [DBPQKR] 1674
Failure Code [DDNRKA] 1682
Failure Code [DDNRKY] 1684
Failure Code [DDNS00] 1686
Failure Code [DFB1KZ] 1688
Failure Code [DFB2KZ] 1690
Failure Code [DFB3L8] 1692
Failure Code [DFB4L8] 1694
Failure Code [DFB5KZ] 1696
Failure Code [DFB6KZ] 1698
Failure Code [DGH2KA] 1700
Failure Code [DGH2KB] 1702
Failure Code [DHA4KA] 1704
Failure Code [DHAAMA] 1706
Failure Code [DHACMA] 1708
Failure Code [DHPAMA] 1710
Failure Code [DHPBMA] 1713
Failure Code [DHS3MA] 1716
Failure Code [DHS4MA] 1719
Failure Code [DHS8MA] 1722
Failure Code [DHS9MA] 1725
Failure Code [DHSAMA] 1728
Failure Code [DHSBMA] 1731
Failure Code [DHSCMA] 1734
Failure Code [DHSDMA] 1737
Failure Code [DHSFMA] 1740
Failure Code [DHSGMA] 1743
Failure Code [DHSHMA] 1746
Failure Code [DHSJMA] 1749
Failure Code [DHX1MA] 1752
Failure Code [DKR0MA] 1754
Failure Code [DKR1MA] 1757
Failure Code [DKULKA] 1760
Failure Code [DKULKB] 1762
Failure Code [DKULKY] 1764
Failure Code [DLM3KA] 1766
Failure Code [DLM3KB] 1768
Failure Code [DLM3MB] 1770
Failure Code [DR10KA] 1771
Failure Code [DR12KA] 1774
Failure Code [DR20KA] 1776
Failure Code [DR21KX] 1778
Failure Code [DR30KA] 1780
Failure Code [DR31KX] 1782
Failure Code [DR40KA] 1784
Failure Code [DUMBKA] 1786
Failure Code [DUMBKB] 1789
Failure Code [DV20KB] 1791
Failure Code [DW43KA] 1793
Failure Code [DW43KB] 1795
Failure Code [DW43KY] 1797
Failure Code [DW45KA] 1799
Failure Code [DW45KB] 1802
Failure Code [DW45KY] 1805
Failure Code [DW4CKY] 1807
Failure Code [DW7BKA] 1808
Failure Code [DW7BKB] 1810
Failure Code [DW7BKY] 1812
Failure Code [DW91KA] 1813
Failure Code [DW91KB] 1815
Failure Code [DW91KY] 1817
Failure Code [DWA2KA] 1819
Failure Code [DWA2KB] 1821
Failure Code [DWA2KY] 1823
Failure Code [DWK0KA] 1825
Failure Code [DWK0KB] 1827
Failure Code [DWK0KY] 1829
Failure Code [DWK2KA] 1831
Failure Code [DWK2KB] 1833
Failure Code [DWK2KY] 1835
Failure Code [DWK8KA] 1837
Failure Code [DWK8KB] 1839
Failure Code [DWK8KY] 1841
Failure Code [DX16KA] 1843
Failure Code [DX16KB] 1845
Failure Code [DXA8KA] 1847
Failure Code [DXA8KB] 1849
Failure Code [DXA9KA] 1851
Failure Code [DXA9KB] 1853
Failure Code [DXE0KA] 1855
Failure Code [DXE0KB] 1857
Failure Code [DXE4KA] 1859
Failure Code [DXE4KB] 1861
Failure Code [DXE4KY] 1863
Failure Code [DXE5KA] 1865
Failure Code [DXE5KB] 1867
Failure Code [DXE6KA] 1869
Failure Code [DXE6KB] 1871
Failure Code [DXE7KA] 1873
Failure Code [DXE7KB] 1875
Failure Code [DXE7KY] 1877
Failure Code [DXE8KA] 1879
Failure Code [DXE8KB] 1881
Failure Code [DXE8KY] 1883
Failure Code [DXE9KA] 1885
Failure Code [DXE9KB] 1887
Failure Code [DXE9KY] 1889
Failure Code [DXEAKA] 1891
Failure Code [DXEAKB] 1893
Failure Code [DXEAKY] 1895
Failure Code [DXEKKA] 1897
Failure Code [DXEKKB] 1899
Failure Code [DXEKKY] 1901
Failure Code [DXELKA] 1903
Failure Code [DXELKB] 1905
Failure Code [DXELKY] 1907
Failure Code [DY20KA] 1909
Failure Code [DY20MA] 1911
Failure Code [DY2CKB] 1913
Failure Code [DY2DKB] 1916
Failure Code [DY2EKB] 1918
Failure Code [F311KA] 1920
Failure Code [F311KB] 1922
Failure Code [F312KA] 1924
Failure Code [F312KB] 1926
Failure Code [F313KA] 1928
Failure Code [F313KB] 1930
Failure Code [F314KA] 1933
Failure Code [F314KB] 1935
Failure Code [F315KB] 1937
Failure Code [F315KY] 1939
Failure Code [F316KB] 1941
Failure Code [F316KY] 1943
Failure Code [F318KB] 1945
Failure Code [F318KY] 1948
Failure Code [F31AKB] 1950
Failure Code [F31AKY] 1952
Failure Code [F31BKB] 1954
Failure Code [F31BKY] 1956
Failure Code [F31CKB] 1958
Failure Code [F31CKY] 1960
Failure Code [F31DKB] 1962
Failure Code [F31DKY] 1964
Failure Code [F31EKB] 1966
Failure Code [F31EKY] 1968
Troubleshooting of Electrical System (E-Mode) 1970
E-1 Engine Does Not Start (Engine Does Not Crank) 1970
E-2 Manual Preheating System Does Not Operate 1976
E-3 Automatic Preheating System Does Not Operate 1979
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1981
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1983
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1986
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1987
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1988
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1989
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1990
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1991
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1992
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1993
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1994
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation 1995
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum 1996
E-17 Display of Fuel Gauge is Different from Actual Fuel Level 1998
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1999
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 2000
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 2001
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 2003
E-22 Some Areas of Machine Monitor Screen are Not Shown 2004
E-23 Function Switch Does Not Operate 2005
E-24 Automatic Warm-up System Does Not Work (in Cold Weather) 2006
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 2007
E-26 Auto-Decelerator is Not Operated or Canceled with Lever 2008
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 2009
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 2010
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 2011
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 2012
E-31 Alarm Buzzer Cannot be Canceled 2014
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position 2015
E-33 Service Mode Cannot be Selected 2016
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 2017
E-35 All Work Equipment, Swing and Travel Do Not Lock 2019
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 2020
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 2023
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor 2025
E-39 One-Touch Power Maximizing Function is Not Cancelled 2027
E-40 Alarm Does Not Sound During Travel 2028
E-41 Alarm Does Not Stop When Machine Stops 2030
E-42 Horn Does Not Sound 2031
E-43 Horn Does Not Stop 2035
E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 2037
E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2038
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated 2040
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2041
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2042
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function 2043
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function 2044
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2045
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2046
E-53 “Swing” is Not Shown Correctly with Monitoring Function 2047
E-54 “Travel” is Not Shown Correctly with Monitoring Function 2048
E-55 Service is Not Shown Correctly with Monitoring Function 2049
E-56 Attachment Hydraulic Circuit Cannot be Changed 2051
E-57 KOMTRAX System Does Not Operate Correctly 2052
E-58 Machine Push-up Function Cannot be Canceled 2053
E-59 Machine Push-Up Function Does Not Operate 2055
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2056
Information Shown in Troubleshooting Table (H-Mode) 2056
System Chart of Hydraulic and Mechanical Systems 2057
Failure Mode and Cause Table 2059
H-1 All Work Equipment, Swing and Travel Do Not Work 2067
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2068
H-3 Fine Control Performance or Response is Unsatisfactory 2070
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2071
H-5 Engine Speed Drops Largely or Engine Stops 2072
H-6 Speed or Power of Boom is Low 2074
H-7 Arm Speed or Power is Low 2080
H-8 Bucket Speed or Power is Low 2085
H-9 Work Equipment Does Not Move in Single Operation 2088
H-10 Hydraulic Drift of Boom is Large 2089
H-11 Hydraulic Drift of Arm is Large 2091
H-12 Hydraulic Drift of Bucket is Large 2093
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2094
H-14 Time Lag of Work Equipment is Large 2095
H-15 One-Touch Power Maximizing Function Does Not Operate 2096
H-16 Machine Push-Up Function Does Not Operate 2097
H-17 Attachment Circuit Cannot be Changed 2098
H-18 Oil Flow in Attachment Circuit Cannot be Changed 2099
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2100
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely 2101
H-21 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 2102
H-22 Machine Does Not Travel Straight 2103
H-23 Machine is Not Steered Correctly or Steering Power is Low 2105
H-24 Travel Speed is Low 2108
H-25 One of Tracks Does Not Run 2110
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2111
H-27 Machine Does Not Swing to Right or Left 2112
H-28 Upper Structure Swings Only to Right or Left 2113
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 2114
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction 2115
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2116
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2117
H-33 Shock is Large When Upper Structure Stops Swing Operation 2118
H-34 There is Large Unusual Noise When It Stops Swing Operation 2119
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2120
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2121
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2122
H-38 Unusual Noise is Heard from Around Fan 2123
H-39 Quick coupler cylinder will not extend 2124
H-40 Quick coupler cylinder will not retract (but buzzer does not sound) 2126
H-41 Buzzer Does Not Operate (but Quick Coupler Cylinder Does Retract) 2128
H-42 Quick coupler cylinder extends and retracts slowly 2129
Troubleshooting of Engine (S-Mode) 2130
Information Shown in Troubleshooting Table (S-Mode) 2130
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2131
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2132
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2133
S-4 Engine Startability is Unsatisfactory 2134
S-5 Engine Does Not Pick Up Smoothly 2136
S-6 Engine Stops During Operation 2138
S-7 Engine Runs Rough or is Not Stable 2140
S-8 Engine Lacks Power 2141
S-9 KDPF Becomes Clogged in a Short Time 2143
S-10 Engine Oil Consumption is Excessive 2145
S-11 Oil Becomes Dirty Quickly 2146
S-12 Fuel Consumption is Excessive 2147
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2148
S-14 Oil Pressure Drops 2149
S-15 Fuel Mixes Into Engine Oil 2151
S-16 Water Mixes Into Engine Oil (Milky) 2152
S-17 Coolant Temperature Increases Too High (Overheating) 2153
S-18 Unusual Noise is Heard 2154
S-19 Vibration is Excessive 2155
S-20 Air Cannot be Bled from Fuel Circuit 2156
S-21 Active Regeneration is Done Frequently 2157
S-22 Active Regeneration Continues Long 2159
S-23 White Smoke is Exhausted During Active Regeneration 2160
S-24 DEF Consumption is Excessive 2161
S-25 There is Unusual Smell (Irritating Odor) 2163
S-26 Foreign Materials Enter DEF (DEF Increases) 2164
50 Disassembly and Assembly 2165
Table of Contents 2166
Precautions Before Work 2172
Related Information on Disassembly and Assembly 2173
How to Read This Manual 2173
Coating Materials List 2174
Special Tool List 2179
Sketches of Special Tools 2191
Engine and Cooling System 2197
Remove and Install Supply Pump Assembly 2197
Remove Supply Pump Assembly 2197
Install Supply Pump Assembly 2203
Remove and Install Injector Assembly 2212
How to Remove Injector Assembly 2212
How to Install Injector Assembly 2218
Remove and Install Fuel Doser Assembly 2228
How to Remove Fuel Doser 2228
How to Install Fuel Doser 2229
Remove and Install Cylinder Head Assembly 2231
How to Remove Cylinder Head Assembly 2232
How to Install Cylinder Head Assembly 2241
Remove and Install EGR Valve Assembly 2254
Remove EGR Valve Assembly 2254
Install EGR Valve Assembly 2256
Remove and Install EGR Cooler Assembly 2258
How to Remove EGR Cooler Assembly 2258
How to Install EGR Cooler Assembly 2262
Remove and Install Starter Assembly 2268
Remove Starting Motor Assembly 2268
Install Starting Motor Assembly 2269
Remove and Install Alternator Belt 2271
Remove Alternator Belt 2271
Install Alternator Belt 2274
Remove and Install Radiator Assembly 2279
How to Remove Radiator Assembly 2279
How to Install Radiator Assembly 2281
Remove and Install Cooling Fan and Fan Motor Assembly 2284
Remove Cooling Fan and Fan Motor Assembly 2284
Install Cooling Fan and Fan Motor Assembly 2288
Remove and Install Hydraulic Oil Cooler Assembly 2293
How to Remove Hydraulic Oil Cooler Assembly 2293
How to Install Hydraulic Oil Cooler Assembly 2295
Remove and Install Aftercooler Assembly 2297
Remove Aftercooler Assembly 2297
Install Aftercooler Assembly 2299
Remove and Install Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205) 2303
How to Remove Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205) 2304
How to Install Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205) 2322
Remove and Install Engine and Main Pump Assembly (Applicable Machine: 86206 and up) 2341
How to Remove Engine and Main Pump Assembly (Applicable Machine: 86206 and up) 2342
How to Install Engine and Main Pump Assembly (Applicable Machine: 86206 and up) 2360
Remove and Install Engine Front Oil Seal 2379
How to Remove Engine Front Oil Seal 2380
How to Install Engine Front Oil Seal 2382
Remove and Install Engine Rear Oil Seal 2386
How to Remove Engine Rear Oil Seal 2387
How to Install Engine Rear Oil Seal 2390
Remove and Install Engine Hood Assembly 2396
How to Remove Engine Hood Assembly 2396
How to Install Engine Hood Assembly 2404
Remove and Install Fuel Tank Assembly 2415
Remove Fuel Tank Assembly 2415
Install Fuel Tank Assembly 2419
Remove and Install DEF Tank Assembly 2423
How to Remove DEF Tank Assembly 2423
How to Install DEF Tank Assembly 2429
Remove and Install DEF Tank Sensor Flange Assembly 2434
How to Remove DEF Tank Sensor Flange Assembly 2434
How to Install DEF Tank Sensor Flange Assembly 2441
Remove and Install DEF Tank Sensor 2447
Remove DEF Tank Sensor 2447
Install DEF Tank Sensor 2447
Remove and Install DEF Tank Filler Port Filter 2454
Remove DEF Tank Filler Port Filter 2454
Install DEF Tank Filler Port Filter 2456
Remove and Install KDPF Assembly (Applicable Machine: 85001 to 86205) 2459
How to Remove KDPF Assembly (Applicable Machine: 85001 to 86205) 2459
How to Install KDPF Assembly (Applicable Machine: 85001 to 86205) 2463
Remove and Install KDPF Assembly (Applicable Machine: 86206 and up) 2468
How to Remove KDPF Assembly (Applicable Machine: 86206 and up) 2468
How to Install KDPF Assembly (Applicable Machine: 86206 and up) 2472
Disassemble and Assemble of KDPF Assembly (Applicable Machine:85001 to 86205) 2476
How to Disassemble KDPF Assembly (Applicable Machine: 85001 to 86205) 2477
How to Assemble KDPF Assembly (Applicable Machine: 85001 to 86205) 2482
Disassemble and Assemble KDPF Assembly (Applicable Machine:86206 and up) 2489
How to Disassemble KDPF Assembly (Applicable Machine:86206 and up) 2490
How to Assemble KDPF Assembly (Applicable Machine: 86206 and up) 2492
Remove and Install SCR Assembly (Applicable Machine: 85001 to 86205) 2497
How to Remove SCR Assembly (Applicable Machine: 85001 to 86205) 2497
How to Install SCR Assembly (Applicable Machine: 85001 to 86205) 2500
Remove and Install SCR Assembly (Applicable Machine: 86206 and up) 2504
How to Remove SCR Assembly (Applicable Machine: 86206 and up) 2504
How to Install SCR Assembly (Applicable Machine: 86206 and up) 2507
Remove and Install KDPF and SCR Assembly (Applicable Machine: 85001 to 86205) 2511
How to Remove KDPF and SCR Assembly (Applicable Machine: 85001 to 86205) 2511
How to Install KDPF and SCR Assembly (Applicable Machine: 85001 to 86205) 2516
Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2521
How to Remove KDPF and SCR Assembly (Applicable Machine: 86206 and up) 2521
How to Install KDPF and SCR Assembly (Applicable Machine: 86206 and up) 2526
Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205) 2531
How to Remove KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205) 2531
Install KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205) 2536
Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2545
How to Remove KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2545
Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up) 2550
Remove and Install Bellows Pipe Assembly 2559
How to Remove Bellows Pipe Assembly 2559
How to Install Bellows Pipe Assembly 2561
Remove and Install KCCV Assembly 2565
Remove KCCV Assembly 2565
Install KCCV Assembly 2566
Remove and Install DEF Mixing Tube 2570
Remove DEF Mixing Tube 2570
Install DEF Mixing Tube 2575
Remove and Install DEF Injector 2581
Remove DEF Injector 2581
Install DEF Injector 2585
Remove and Install DEF Pump 2590
How to Remove DEF Pump (Applicable Machine: 85001 to 86052) 2590
How to Install DEF Pump (Applicable Machine: 85001 to 86052) 2592
How to Remove DEF Pump (Applicable Machine: 86053 and up) 2593
How to Install DEF Pump (Applicable Machine: 86053 and up) 2595
Remove and Install DEF Hose 2597
How to Remove DEF Hose (Applicable Machine: 85001 to 86052) 2597
How to Install DEF Hose (Applicable Machine: 85001 to 86052) 2602
How to Remove DEF Hose (Applicable Machine: 86053 and up) 2610
How to Install DEF Hose (Applicable Machine: 86053 and up) 2615
Remove and Install Air Cleaner Assembly 2623
Remove Air Cleaner Assembly 2623
Install Air Cleaner Assembly 2624
Remove and Install Air Conditioner Compressor Assembly 2627
Remove Air Conditioner Compressor Assembly 2627
How to Install Air Conditioner Compressor Assembly 2630
Remove and Install Air Conditioner Condenser Assembly 2634
How to Remove Air Conditioner Condenser Assembly 2634
How to Install Air Conditioner Condenser Assembly 2635
Power Train 2637
Remove and Install Travel Motor and Final Drive Assembly 2637
Remove Travel Motor and Final Drive Assembly 2637
Install Travel Motor and Final Drive Assembly 2638
Disassemble and Assemble Final Drive Assembly 2639
Disassemble Final Drive Assembly 2639
Assemble Final Drive Assembly 2644
Remove and Install Swing Motor and Swing Machinery Assembly 2650
Remove Swing Motor and Swing Machinery Assembly 2650
Install Swing Motor and Swing Machinery Assembly 2651
Disassemble and Assemble Swing Machinery Assembly 2653
Disassemble Swing Machinery Assembly 2653
Assemble Swing Machinery Assembly 2657
Remove and Install Swing Circle Assembly 2663
Remove Swing Circle Assembly 2663
Install Swing Circle Assembly 2663
Undercarriage and Frame 2665
Separate and Connect Track Assembly 2665
Separate Track Assembly 2665
Install Track Assembly 2667
Remove and Install Sprocket 2670
Remove Sprocket 2670
Install Sprocket 2670
Remove and Install Idler and Idler Cushion Assembly 2672
Remove Idler and Idler Cushion Assembly 2672
Install Idler and Idler Cushion Assembly 2673
Disassemble and Assemble Idler Assembly 2675
Disassemble Idler Assembly 2675
Assemble Idler Assembly 2677
Disassemble and Assemble Idler Cushion Assembly 2682
Disassemble Idler Cushion Assembly 2683
Assemble Idler Cushion Assembly 2685
Disassemble and Assemble Track Roller Assembly 2688
Disassemble Track Roller Assembly 2689
Assemble Track Roller Assembly 2690
Disassemble and Assemble Carrier Roller Assembly 2694
Disassemble Carrier Roller Assembly 2694
Assemble Carrier Roller Assembly 2696
Remove and Install Revolving Frame Assembly 2699
Remove Revolving Frame Assembly 2699
Install Revolving Frame Assembly 2701
Remove and Install Counterweight Assembly 2704
Remove Counterweight Assembly 2704
Install Counterweight Assembly 2705
Hydraulic System 2707
Remove and Install Center Swivel Joint Assembly 2707
Remove Center Swivel Joint Assembly 2707
Install Center Swivel Joint Assembly 2709
Disassemble and Assemble Center Swivel Joint Assembly 2711
Disassemble Center Swivel Joint Assembly 2712
Assemble Center Swivel Joint Assembly 2712
Remove and Install Hydraulic Tank Assembly 2714
Remove Hydraulic Tank Assembly 2714
How to Install Hydraulic Tank Assembly 2719
Remove and Install Main Pump Assembly 2725
Remove Main Pump Assembly 2725
Install Main Pump Assembly 2729
Remove and Install Control Valve Assembly 2735
How to Remove Control Valve Assembly 2735
How to Install Control Valve Assembly 2740
Disassemble and Assemble Control Valve Assembly 2746
Replace Pressure Compensation Valve Seal Ring 2747
Assemble Control Valve Assembly 2748
Disassemble and Assemble Work Equipment PPC Valve Assembly 2753
Disassemble Work Equipment PPC Valve Assembly 2753
How to Assemble Work Equipment PPC Valve Assembly 2754
Disassemble and Assemble Travel PPC Valve Assembly 2756
Disassemble Travel PPC Valve Assembly 2756
How to Assemble Travel PPC Valve Assembly 2757
Work Equipment 2759
Remove and Install Work Equipment Assembly 2759
Remove Work Equipment Assembly 2760
Install Work Equipment Assembly 2763
Remove and Install Boom Anti-drop Valve Assembly 2767
Remove Boom Anti-drop Valve Assembly 2767
Install Boom Anti-drop Valve Assembly 2769
Remove and Install Arm Anti-Drop Valve Assembly 2770
Remove Arm Anti-Drop Valve Assembly 2770
Install Arm Anti-Drop Valve Assembly 2772
Disassemble and Assemble Anti-Drop Valve Assembly 2773
Disassemble Anti-Drop Valve Assembly 2773
Assemble Anti-Drop Valve Assembly 2773
Disassemble and Assemble Work Equipment Cylinder Assembly 2774
How to Disassemble Work Equipment Cylinder Assembly 2774
How to Assemble Work Equipment Cylinder Assembly 2777
CAB Related Parts 2781
Remove and Install Operator Cab Assembly 2781
How to Remove Operator Cab Assembly 2781
Install Operator CAB Assembly 2788
Remove and Install Operator Cab Glass (Adhered Glass) 2795
Remove Operator CAB Glass (Adhered Glass) 2797
Install Operator CAB Glass (Adhered Glass) 2797
Remove and Install Front Window Assembly 2807
Remove Front Window Assembly 2807
Install Front Window Assembly 2810
Remove and Install Floor Frame Assembly 2816
How to Remove Floor Frame Assembly 2817
How to Install Floor Frame Assembly 2823
Remove and Install Air Conditioner Unit Assembly 2831
Remove Air Conditioner Unit Assembly 2831
Install Air Conditioner Unit Assembly 2837
Remove and Install Operator Seat 2844
Remove Operator’s Seat 2844
Install Operator’s Seat 2846
How to Remove and Install Seat Belt 2849
How to Remove Seat Belt 2849
How to Install Seatbelt 2850
Remove and Install Work Equipment Control Lever Assembly 2851
How to Remove Work Equipment Control Lever Assembly 2851
How to Install Work Equipment Control Lever Assembly 2857
Remove and Install Front Wiper Assembly 2866
Remove Front Wiper Assembly 2866
Install Front Wiper Assembly 2871
Electrical System 2880
Remove and Install Engine Controller Assembly 2880
Remove Engine Controller Assembly 2880
Install Engine Controller Assembly 2881
Remove and Install Pump Controller Assembly 2883
Remove Pump Controller Assembly 2883
Install Pump Controller Assembly 2886
Remove and Install KomVision Controller Assembly 2891
Remove KomVision Controller Assembly 2891
Install KomVision Controller Assembly 2892
Remove and Install Machine Monitor Assembly 2893
Remove Machine Monitor Assembly 2893
Install Machine Monitor Assembly 2896
Remove and Install Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205 2900
How to Remove Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205) 2900
How to Install Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205) 2901
Remove and Install Pump Swash Plate Sensor (Applicable Machine: 86206 and up) 2902
How to Remove Pump Swash Plate Sensor (Applicable Machine: 86206 and up) 2902
How to Install Pump Swash Plate Sensor (Applicable Machine: 86206 and up) 2903
Remove and Install Mass Air Flow and Temperature Sensor 2904
How to Remove Mass Air Flow and Temperature Sensor 2904
How to Install Mass Air Flow and Temperature Sensor 2905
Remove and Install KCCV Crankcase Pressure Sensor 2907
How to Remove KCCV Crankcase Pressure Sensor 2907
How to Install KCCV Crankcase Pressure Sensor 2908
Remove and Install SCR Temperature Sensor 2910
Remove SCR Temperature Sensor 2910
Install SCR Temperature Sensor 2912
Remove and Install Rearview Camera 2914
Remove Rearview Camera 2914
Install Rearview Camera 2915
Remove and Install KomVision Camera 2917
Remove KomVision Camera 2917
Install KomVision Camera 2918
Remove and Install Gateway Function Controller Assembly 2920
Remove Gateway Function Controller Assembly 2920
How to Install Gateway Function Controller Assembly 2925
Remove and Install Communication Terminal Wiring Harness 2930
Remove Communication Terminal Wiring Harness 2930
Install Communication Terminal Wiring Harness 2938
Remove and Install Communication Terminal 2947
Remove Communication Terminal 2947
Install Communication Terminal 2949
60 Maintenance Standard 2953
Table of Contents 2954
Engine and Cooling System 2955
Maintenance Standard for Engine Mount 2955
Maintenance Standard for Cooling System 2956
Maintenance Standard for Cooling Fan Pump 2957
Maintenance Standard for Servo Valve 2958
Maintenance Standard for Cooling Fan Motor 2959
Power Train 2960
Maintenance Standard for Swing Circle 2960
Maintenance Standard for Swing Machinery 2961
Maintenance Standard for Final Drive 2963
Maintenance Standard for Sprocket 2965
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2966
Undercarriage and Frame 2967
Maintenance Standard for Track Frame and Idler Cushion 2967
Maintenance Standard for Idler 2969
Maintenance Standard for Track Roller 2971
Maintenance Standard for Carrier Roller 2973
Maintenance Standard for Track Shoes 2974
Maintenance Standard for Triple Shoes 2977
Hydraulic System 2978
Maintenance Standard for Main Pump 2978
Maintenance Standard for Swing Motor 2980
Maintenance Standard for Travel Motor 2983
Maintenance Standard for Control Valve 2986
Maintenance Standard for Boom Anti-Drop Valve 2997
Maintenance Standard for Arm Anti-Drop Valve 2999
Maintenance Standard for Work Equipment and Swing PPC Valve 3001
Maintenance Standard for Travel PPC Valve 3004
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 3007
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 3008
Maintenance Standard for Solenoid Valve 3010
Maintenance Standard for Attachment Circuit Selector Valve 3011
Maintenance Standard for Center Swivel Joint 3012
Work Equipment 3013
Maintenance Standard for Work Equipment Linkage 3013
Dimensions of Arm 3018
Dimensions of Bucket 3020
Maintenance Standard for Boom Cylinder 3022
Maintenance Standard for Arm Cylinder 3023
Maintenance Standard for Bucket Cylinder 3024
80 Appendix 3025
Table of Contents 3026
Precautions Before Work 3028
Air Conditioner System 3029
Precautions for Refrigerant 3029
Air Conditioner Component 3030
Specifications of Air Conditioner 3032
Structure and Function of Refrigeration Cycle 3033
Outline of Refrigeration Cycle 3034
Component Parts of Air Conditioner System 3036
Air Conditioner Unit 3036
Configuration Diagram of Air Conditioner Unit 3036
Function of Air Conditioner Unit 3038
Component Parts of Air Conditioner Unit 3040
Function of Evaporator as Air Conditioner Unit Component 3041
Function of Heater Core as Air Conditioner Unit Component 3041
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3041
Function of Servo Motor as Air Conditioner Unit Component 3041
Structure of Expansion Valve as Air Conditioner Unit Component 3042
Function of Expansion Valve as Air Conditioner Unit Component 3042
Operate Expansion Valve as Air Conditioner Unit Component 3042
Function of Dual Pressure Switch 3043
Air Conditioner Controller 3044
Structure of Air Conditioner Controller 3044
Compressor 3045
Structure of Compressor 3045
Specifications of Compressor 3045
Function of Compressor 3045
Condenser 3046
Structure of Condenser 3046
Specifications of Condenser 3046
Function of Condenser 3046
Receiver Drier 3047
Structure of Receiver Dryer 3047
Specifications of Receiver Dryer 3047
Function of Receiver Dryer 3047
Air Conditioner Related Sensors 3048
Structure of Sunlight Sensor 3048
Function of Sunlight Sensor 3048
Structure of Outside Temperature Sensor 3048
Function of Outside Air Temperature Sensor 3048
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3050
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3052
System Diagram of Air Conditioner 3054
Input and Output Signals of Air Conditioner Controller 3055
Function of Air Conditioner Controller 3056
Locations of Air Conditioner Parts and Layout of Connectors 3057
Examine Air Leakage (Duct) 3061
How to Examine Air Leakage (Duct) 3061
Examine Air Conditioner with Self-Diagnosis Function 3063
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3064
Examine Vent (Mode) Changeover 3065
How to Examine Vent (Mode) Changeover 3065
Examine Fresh/Recirc Air Changeover 3067
How to Examine Fresh/Recirc Air Changeover 3067
Examine Sunlight Sensor 3068
How to Examine Sunlight Sensor 3068
Examine Refrigerant (Dual) Pressure Switch 3069
How to Examine Refrigerant (Dual) Pressure Switch 3069
Examine Relay 3070
How to Examine Relay 3070
Air Conditioner Troubleshooting Chart 1 3071
Air Conditioner Troubleshooting Chart 2 3072
Information Shown in Troubleshooting Table 3075
Failure Code [879AKA] 3076
Failure Code [879AKB] 3077
Failure Code [879BKA] 3078
Failure Code [879BKB] 3080
Failure Code [879CKA] 3082
Failure Code [879CKB] 3083
Failure Code [879DKZ] 3084
Failure Code [879EMC] 3086
Failure Code [879FMC] 3087
Failure Code [879GKX] 3088
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3090
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3092
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3095
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3097
Troubleshooting by Gauge Pressure 3099
Connect Service Tool 3102
How to Connect Service Tool 3102
Precautions for Disconnection and Connection of Air Conditioner Piping 3104
Handle Compressor Oil 3106
90 Circuit Diagrams 3109
Table of Contents 3110
Hydraulic Circuit Diagram 3111
Symbols Used in Hydraulic Circuit Diagram 3111
Hydraulic Circuit Diagram (1/3) 3115
Hydraulic Circuit Diagram (2/3) 3117
Hydraulic Circuit Diagram (3/3) 3119
Electrical Circuit Diagram 3121
Symbols Used in Electric Circuit Diagram 3121
Electrical Circuit Diagram (1/11) 3125
Electrical Circuit Diagram (2/11) 3127
Electrical Circuit Diagram (3/11) 3129
Electrical Circuit Diagram (4/11) 3131
Electrical Circuit Diagram (5/11) 3133
Electrical Circuit Diagram (6/11) 3135
Electrical Circuit Diagram (7/11) 3137
Electrical Circuit Diagram (8/11) 3139
Electrical Circuit Diagram (9/11) 3141
Electrical Circuit Diagram (10/11) 3143
Electrical Circuit Diagram (11/11) 3145
Index 3147

S.V  21/12/24