Komatsu PC700LC-11 PC700LC-11E0 Excavator Shop Manual SEN06957-03 PDF

Description

Komatsu PC700LC-11 PC700LC-11E0 Excavator Shop Manual SEN06957-03 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu PC700LC-11 PC700LC-11E0 Excavator Shop Manual SEN06957-03 – PDF DOWNLOAD 

Language : English
Pages : 2920
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC700LC-11 PC700LC-11E0 Excavator Shop Manual SEN06957-03 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 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.

TABLE OF CONTENTS:

Komatsu PC700LC-11 PC700LC-11E0 Excavator Shop Manual SEN06957-03 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 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 for Disposing of Waste Materials 38
Procedures for Exhaust Gas Regulations 39
Precautions for DEF 40
General Character and Precautions for Handling 40
Precautions for Adding 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
How to Disconnect and Connect Deutsch Connector 65
How to Disconnect and Connect Slide Lock Type Connector 66
How to Disconnect and Connect Connector with Lock to Pull 68
How to Disconnect and Connect Connector with Lock to Push 69
How to 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 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC700LC-11 93
Specification Drawing: PC700LC-11E0 95
Working Range Drawings 96
Working Range: PC700LC-11 96
Working Range Drawings: PC700LC-11E0 97
Specifications 98
Specifications: PC700LC-11 98
Specifications: PC700LC-11E0 101
Weight Table 104
Weight Table: PC700LC-11 104
Weight Table: PC700LC-11E0 106
Table Of Fuel, Coolant, And Lubricants: PC700LC-11 108
Table Of Fuel, Coolant, And Lubricants: PC700LC-11E0 109
10 Structure and Function 111
Table of Contents 112
Urea SCR System 116
Layout Drawing of Urea SCR System 116
Urea SCR System Diagram 121
Function of Urea SCR System 122
Function of DEF System 122
Inducement Strategy 124
Component Parts of Urea SCR System 132
DEF Mixing Tube 132
SCR Assembly 132
DEF Tank 135
DEF Pump 137
DEF Injector 138
DEF Hose 139
DEF Tank Heating Valve 140
Boot-up System 141
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 141
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 142
System Operating Lamp System 143
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 143
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 143
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 143
Function of System Operating Lamp System (Machine with Gateway Function Controller) 144
Battery Isolator 146
Function of Battery Isolator 146
Engine System 147
Layout Drawing of Engine System 147
Function of Engine System 148
Engine Control System 149
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 149
System Diagram of Engine Control System (Machine with Gateway Function Controller) 149
Function of Engine Control System (Machine with KOMTRAX Terminal) 150
Function of Engine Control System (Machine with Gateway Function Controller) 153
Auto-Deceleration System 156
System Diagram of Auto-Deceleration System 156
Function of Auto-Deceleration System 156
Operation of Auto-Deceleration System 157
Automatic Low Idle System 158
Automatic Low Idle System Diagram 158
Function of Automatic Low Idle System 158
Operation of Automatic Low Idle System 159
Engine Automatic Warm-up System 160
System Diagram of Engine Automatic Warm-up System 160
Function of Engine Automatic Warm-up System 161
Overheat Prevention System 163
Overheat Prevention System Diagram 163
Function of Overheat Prevention System 164
Turbocharger Protection System 165
System Diagram of Turbocharger Protection System 165
Function of Turbocharger Protection System 166
Automatic Idle Stop System 167
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 167
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 167
Function of Automatic Idle Stop System 168
Component Parts of Engine System 171
PTO 171
VGT 172
EGR System 175
EGR Valve 177
EGR Cooler 179
KCCV System 180
KCCV Ventilator 182
KDPF 184
Cooling System 189
Layout Drawing of Cooling System 189
Specifications of Cooling System 190
Fan Speed Control System of Hydraulic Fan 191
Fan Speed Control System Diagram of Hydraulic Fan 191
Function of Fan Speed Control System of Hydraulic Fan 192
Engine Output Control System of Hydraulic Fan 193
Engine Output Control System Diagram of Hydraulic Fan 193
Function of Engine Output Control System of Hydraulic Fan 193
Fan Reverse Rotation System of Hydraulic Fan 195
Fan Reverse Rotation System Diagram of Hydraulic Fan 195
Function of Fan Reverse Rotation System of Hydraulic Fan 195
Component Parts of Cooling System 196
Cooling Fan Pump 196
Cooling Fan Motor 204
Control System 211
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 211
Layout Drawing of Control System (Machine with Gateway Function Controller) 213
Machine Monitor System 215
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 215
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 216
Function of Machine Monitor System 216
KomVision System 218
Layout Drawing of KomVision System 218
System Diagram of KomVision System 220
Function of KomVision System 220
KOMTRAX System 222
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 222
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 222
Function of KOMTRAX System 223
Component Parts of Control System 224
Machine Monitor 224
KomVision Controller 237
KomVision Camera 241
KOMTRAX Terminal 241
Gateway Function Controller 244
Communication Terminal 247
Pump Controller 249
Resistor for TVC Valve 253
CAN Terminating Resistor 253
PPC Oil Pressure Switch 254
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
OLSS 268
Structure of OLSS 268
Function of OLSS 268
Pump Swash Plate Angle (Oil Flow) Control 269
Engine and Pump Combined Control System 280
Engine and Pump Combined Control System Diagram 280
Function of Engine and Pump Combined Control System 282
Component Parts of Hydraulic System 285
Hydraulic Tank 285
Main Pump 287
Pilot Oil Filter 315
Control Valve 315
Variable Back Pressure Valve 335
Work Equipment System 338
Layout Drawing of Work Equipment System 338
One-Touch Power Maximizing System 344
System Diagram of One-Touch Power Maximizing System 344
Function of One-Touch Power Maximizing System 345
Machine Push-up System 346
Machine Push-up System Diagram 346
Function of Machine Push-up System 347
Boom Shockless Control Function 348
Boom Shockless Control Function System Diagram 348
Operation of Boom Shockless Control Function 348
PPC Lock System 349
System Diagram of PPC Lock 349
Function of PPC Lock System 349
Work Equipment and Travel Automatic Lock System 350
System Diagram of Lock Lever Automatic Lock System 350
Function of Work Equipment and Travel Automatic Lock System 350
Operation of Lock Lever Automatic Lock System 351
Attachment Oil Flow Adjuster System 352
Attachment Oil Flow Adjuster System Diagram 352
Function of Attachment Oil Flow Adjuster System 355
Component Parts of Work Equipment System 356
Work Equipment and Swing PPC Valve 356
1st-Line Attachment PPC Valve 360
PPC Shuttle Valve 362
Solenoid Valve 363
Pilot Circuit Accumulator 365
Swing System 367
Layout Drawing of Swing System 367
Swing Control System Diagram 370
Function of Swing Control System 371
Component Parts of Swing System 374
Swing Motor 374
Swing Machinery 385
Swing Circle 386
Travel System 388
Layout Drawing of Travel System 388
System Diagram of Travel Control System 392
Function of Travel Control System 393
Component Parts of Travel System 395
Travel Motor 395
Final Drive 405
Travel PPC Valve 406
Center Swivel Joint 410
Undercarriage and Frame 412
Layout Drawing of Undercarriage 412
Specifications of Undercarriage 412
Work Equipment 413
Structure of Work Equipment 413
Function of Work Equipment 414
Work Equipment Clearance Adjustment Shim 415
Function of Work Equipment Clearance Adjustment Shim 415
Bucket Clearance Adjustment Shim 416
Function of Bucket Clearance Adjustment Shim 416
CAB Related Parts 417
CAB 417
Structure of CAB 417
CAB Mount 418
Structure of CAB Mount 418
Function of CAB Mount 418
CAB Tipping Stopper 419
Structure of CAB Tipping Stopper 419
Function of CAB Tipping Stopper 419
20 Standard Value Table 421
Table of Contents 422
Standard Value Table for Engine 423
Standard Value Table for Engine: PC700LC-11 423
Standard Value Table for Engine: PC700LC-11E0 428
Standard Value Table for Machine 433
Standard Value Table for Machine: PC700LC-11 433
Standard Value Table for Machine: PC700LC-11E0 450
Machine Posture and Procedures to Measure Performance 467
30 Testing and Adjusting 471
Table of Contents 472
Precautions Before Work 475
Related Information on Testing and Adjusting 476
Tools for Testing and Adjusting 476
Sketch of Tools for Testing and Adjusting 485
Engine and Cooling System 487
Examine Engine Speed 487
How to Examine Engine Speed 487
Examine Boost Pressure 490
How to Examine Boost Pressure on Machine Monitor 490
How to Examine Boost Pressure by Testing Tool 491
Examine Exhaust Gas Temperature 492
How to Examine Exhaust Gas Temperature 492
Examine Exhaust Gas Color 494
How to Examine Exhaust Gas Color with the Handy Smoke Checker 494
How to Examine Exhaust Gas Color with Smoke Meter 495
Examine Mass Air Flow and Temperature Sensor 497
How to Examine Mass Air Flow and Temperature Sensor 497
Examine and Adjust Valve Clearance 499
How to Examine Valve Clearance 499
How to Adjust Valve Clearance 500
Examine Compression Pressure 502
How to Examine Compression Pressure 502
Examine Blowby Pressure 505
How to Examine Blowby Pressure 505
Examine Engine Oil Pressure 507
How to Examine Engine Oil Pressure on Machine Monitor 507
How to Examine Engine Oil Pressure by Testing Tool 507
Examine EGR Valve and VGT Oil Pressure 509
How to Examine EGR Valve and VGT Oil Pressure 509
Examine Fuel Pressure 511
How to Examine Fuel Pressure 511
Examine Fuel Return Rate and Leakage 513
How to Examine Fuel Return Rate and Leakage 513
Bleed Air from Fuel System 516
How to Bleed Air from Fuel System 516
Examine Fuel Circuit for Leakage 518
How to Examine Fuel System for Leakage 518
Handle Cylinder Cut-out Mode Operation 520
Handle No-Injection Cranking Operation 521
Examine and Adjust Air Conditioner Compressor Belt Tension 522
How to Examine Air Conditioner Compressor Belt 522
How to Replace Fan Belt 523
Clean Fuel Doser 524
How to Clean Fuel Doser 524
Write Injector Compensation Value to Engine Controller 526
How to Write Injector Compensation Value 526
Write Correction for Ash in Soot Accumulation to Engine Controller 532
How to Write Correction for Ash in Soot Accumulation to Engine Controller 532
Examine SCR Related Functions 533
Examine DEF Pump Raised Pressure 536
Examine Injection Volume from DEF Injector 539
Examine DEF Line Heater Relay 1 543
Examine DEF Line Heater Relay 2 546
Examine DEF Pump Heater Relay 548
Examine DEF Tank Heater Valve 552
Examine SCR Denitration Efficiency 554
Clean DEF Tank 559
How to Clean DEF Tank 559
Clean DEF Pump 563
How to Clean DEF Pump 563
Power Train 569
Examine Swing Circle Bearing Clearance 569
How to Examine Swing Circle Bearing Clearance 569
Undercarriage and Frame 570
Examine and Adjust Track Tension 570
How to Examine Track Tension 570
How to Adjust Track Tension 570
Hydraulic System 572
Release Remained Pressure in Hydraulic Circuit 572
How to Release Remained Pressure in Hydraulic System 572
How to Release Remained Pressure from Swing Motor Circuit 581
How to Release Remained Pressure from Travel Motor Circuit 581
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 582
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 585
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 593
Examine and Adjust Oil Pressure in Control Circuit 597
How to Examine Oil Pressure in Control Circuit 597
How to Adjust Oil Pressure in Control Circuit 598
Examine and Adjust Piston Pump Control Oil Pressure 599
How to Examine TVC Valve Outlet Pressure 599
How to Examine CO and NC Valve Outlet Pressure 600
How to Examine Jet Sensor Outlet Differential Pressure 601
How to Adjust TVC Valve 603
How to Adjust CO and NC Valve 604
How to Adjust Jet Sensor 605
Examine Servo Piston Stroke 606
How to Examine Servo Piston Stroke 606
Examine Outlet Pressure of Solenoid Valve 608
How to Examine Outlet Pressure of Solenoid Valve 608
Operating Condition of Solenoid Valve 609
Examine PPC Valve Outlet Pressure 612
How to Examine Outlet Pressure in PPC Valve 612
Examine PPC Shuttle Valve Outlet Pressure 614
How to Examine PPC Shuttle Valve Outlet Pressure 614
Adjust Play of Work Equipment and Swing PPC Valves 617
How to Adjust Play of Work Equipment and Swing PPC Valves 617
Examine and Adjust Travel Deviation 618
How to Examine Travel Deviation 618
How to Adjust Travel Deviation 618
Examine Cooling Fan Speed 620
How to Examine Cooling Fan Speed 620
Examine Oil Pressure in Fan Pump Circuit 621
How to Examine Oil Pressure in Fan Pump Circuit 621
Examine Fan Pump EPC Electric Current 622
How to Examine Fan Pump EPC Electric Current 622
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 623
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 623
Examine Parts Which Cause Hydraulic Drift of Work Equipment 624
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 624
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 624
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 625
Examine Oil Leakage 626
How to Examine Oil Leakage from Boom Cylinder 626
How to Examine Oil Leakage from Arm Cylinder 627
How to Examine Oil Leakage from Bucket Cylinder 627
How to Examine Oil Leakage from Swing Motor 628
How to Examine Oil Leakage from Travel Motor 628
How to Examine Oil Leakage of Swivel Joint 629
Bleed Air from Hydraulic System 631
How to Bleed Air from Hydraulic System 632
CAB Related Parts 635
Examine CAB Tipping Stopper 635
How to Examine Cab Tipping Stopper 635
How to Adjust Mirrors 636
Procedure to Adjust Machine Left Front Mirror (A) 636
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 637
Procedure to Adjust Machine Right Front Mirror (B) 638
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 638
Electrical System 640
Set and Operate Machine Monitor 640
Operator Mode 643
Function to Show Technician Identification Status Screen 643
Function to Show Operator Identification Input Screen 643
Examine Function by LCD (Liquid Crystal Display) 644
Examine Function of Service Meter 645
Usage Limitation and Maintenance Password Change Function 645
Service Mode 647
How to Operate Service Mode 647
How to See Pre-defined Monitoring Information 649
How to Examine Self-Define Monitor Information 656
Abnormality Record Menu 666
How to See Maintenance Record 671
Maintenance Mode Setting 672
How to Set Phone Number Entry 676
Default Menu 677
Diagnostic Tests Menu 683
Adjustment Menu 693
No-Injection Cranking Operation 697
KOMTRAX Settings Menu 698
How to Show Service Message 700
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 702
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 706
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 708
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 713
Adjust Rearview Camera Angle 715
How to Adjust Rearview Camera Angle 715
Adjust KomVision Camera Angle 717
How to Adjust KomVision Camera Angle 718
Adjust KomVision Related Function 720
Setting of KomVision (Main Setting) 720
Setting of KomVision (Camera Setting) 722
Setting of KomVision (Camera Calibration) 724
KomVision screen – Check 12 m visibility 737
Handle Voltage Circuit of Engine Controller 740
Handle Battery Isolator Switch 741
Examine Diodes 742
How to Examine Diodes by Digital Tester 742
How to Examine Diodes by Analog Tester 742
Pm Clinic 743
Pm Clinic Service 743
Pm Clinic Check Sheet: PC700LC-11 746
Pm Clinic Check Sheet: PC700LC-11E0 763
40 Troubleshooting 779
Table of Contents 780
Precautions Before Work 791
Related Information to Troubleshooting 792
General Troubleshooting Points 792
Troubleshooting Points for Urea SCR System 793
Sequence of Events in Troubleshooting 807
Checks Before Troubleshooting 809
Inspection Procedure Before Troubleshooting 811
Walk-Around Check 811
Test in Accordance with Testing Procedure 813
Examine Fuel Level and Type 813
Examine for Impure Ingredient in Fuel 814
Examine Fuel Prefilter 814
Examine Water Separator, Drain Water and Sediment 814
Replace Fuel Prefilter Cartridge 815
Examine Fuel Main Filter 816
Examine Engine Oil Level (Oil Quantity in Oil Pan) 817
Examine Coolant Level (Reservoir Tank) 819
Examine Air Cleaner Clogging 819
Clean Outer Element 819
Replace Element 822
Examine Hydraulic Oil Level 822
Examine Hydraulic Oil Strainer 824
Examine Hydraulic Oil Filter 824
Examine Oil Level in Swing Machinery Case 825
Examine Oil Level in PTO Case 826
Examine PTO Lubrication Filter Strainer 826
Examine Oil Level in Final Drive Case 827
Bleed Air from Fuel System 827
Bleed Air from Hydraulic System 828
How to Examine Electric Equipment 828
Preparation for Troubleshooting of Electrical System 834
Preparation for Troubleshooting of Machine Monitor 834
Preparation for Troubleshooting of Engine Controller 834
Preparation for Troubleshooting of Pump Controller 834
Preparation for Troubleshooting of KOMTRAX Terminal 835
Preparation for Troubleshooting of Gateway Function Controller 835
How to Disconnect and Connect Connector with a Special Lock 838
Procedure for Troubleshooting 843
Symptom and Troubleshooting Numbers 846
Information Shown in Troubleshooting Table 850
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 852
Connector List and Layout 855
Connector Contact Connection Table 870
T-Branch Box and T-Branch Adapter Table 910
Fuse Location Table 916
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 919
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 923
Failure Code Table 925
Troubleshooting by Failure Code (Display of Code) 944
Failure Code [879AKA] 944
Failure Code [879AKB] 945
Failure Code [879BKA] 946
Failure Code [879BKB] 948
Failure Code [879CKA] 950
Failure Code [879CKB] 951
Failure Code [879DKZ] 952
Failure Code [879EMC] 954
Failure Code [879FMC] 955
Failure Code [879GKX] 956
Failure Code [989L00] 958
Failure Code [989M00] 959
Failure Code [989N00] 960
Failure Code [A1U0N3] 961
Failure Code [A1U0N4] 963
Failure Code [A900FR] 965
Failure Code [A900N6] 966
Failure Code [A900NY] 967
Failure Code [AA10NX] 968
Failure Code [AB00KE] 970
Failure Code [AQ10N3] 972
Failure Code [AS00N3] 974
Failure Code [AS00R2] 976
Failure Code [AS00R3] 977
Failure Code [AS00R4] 978
Failure Code [AS00R5] 979
Failure Code [AS00R6] 980
Failure Code [AS00ZK] 981
Failure Code [AS10KM] 982
Failure Code [AS10NR] 983
Failure Code [AS10NT] 984
Failure Code [B@BAZG] 985
Failure Code [B@BAZK] 986
Failure Code [B@BCNS] 988
Failure Code [B@BCQA] 989
Failure Code [B@BCZK] 991
Failure Code [B@HANS] 993
Failure Code [CA115] 994
Failure Code [CA122] 995
Failure Code [CA123] 997
Failure Code [CA131] 999
Failure Code [CA132] 1001
Failure Code [CA135] 1003
Failure Code [CA141] 1005
Failure Code [CA144] 1007
Failure Code [CA145] 1009
Failure Code [CA153] 1011
Failure Code [CA154] 1014
Failure Code [CA187] 1017
Failure Code [CA221] 1019
Failure Code [CA222] 1021
Failure Code [CA227] 1023
Failure Code [CA234] 1024
Failure Code [CA238] 1025
Failure Code [CA239] 1027
Failure Code [CA249] 1029
Failure Code [CA256] 1031
Failure Code [CA271] 1033
Failure Code [CA272] 1035
Failure Code [CA273] 1036
Failure Code [CA274] 1038
Failure Code [CA322] 1039
Failure Code [CA323] 1041
Failure Code [CA324] 1043
Failure Code [CA325] 1045
Failure Code [CA331] 1047
Failure Code [CA332] 1049
Failure Code [CA343] 1051
Failure Code [CA351] 1052
Failure Code [CA352] 1053
Failure Code [CA356] 1056
Failure Code [CA357] 1058
Failure Code [CA386] 1060
Failure Code [CA441] 1061
Failure Code [CA442] 1063
Failure Code [CA449] 1064
Failure Code [CA451] 1065
Failure Code [CA452] 1067
Failure Code [CA515] 1069
Failure Code [CA516] 1071
Failure Code [CA553] 1073
Failure Code [CA555] 1074
Failure Code [CA556] 1075
Failure Code [CA559] 1076
Failure Code [CA595] 1081
Failure Code [CA687] 1082
Failure Code [CA689] 1084
Failure Code [CA691] 1086
Failure Code [CA692] 1088
Failure Code [CA697] 1090
Failure Code [CA698] 1091
Failure Code [CA731] 1092
Failure Code [CA778] 1093
Failure Code [CA1117] 1096
Failure Code [CA1664] 1097
Failure Code [CA1669] 1101
Failure Code [CA1673] 1102
Failure Code [CA1677] 1103
Failure Code [CA1678] 1104
Failure Code [CA1682] 1105
Failure Code [CA1683] 1107
Failure Code [CA1684] 1109
Failure Code [CA1686] 1111
Failure Code [CA1691] 1112
Failure Code [CA1694] 1115
Failure Code [CA1695] 1117
Failure Code [CA1696] 1118
Failure Code [CA1712] 1120
Failure Code [CA1713] 1123
Failure Code [CA1714] 1125
Failure Code [CA1715] 1126
Failure Code [CA1776] 1127
Failure Code [CA1777] 1130
Failure Code [CA1843] 1133
Failure Code [CA1844] 1135
Failure Code [CA1879] 1138
Failure Code [CA1881] 1141
Failure Code [CA1883] 1143
Failure Code [CA1885] 1147
Failure Code [CA1887] 1149
Failure Code [CA1921] 1151
Failure Code [CA1922] 1154
Failure Code [CA1923] 1159
Failure Code [CA1924] 1161
Failure Code [CA1925] 1163
Failure Code [CA1927] 1165
Failure Code [CA1928] 1167
Failure Code [CA1942] 1169
Failure Code [CA1963] 1170
Failure Code [CA1977] 1174
Failure Code [CA1993] 1177
Failure Code [CA2185] 1180
Failure Code [CA2186] 1182
Failure Code [CA2249] 1184
Failure Code [CA2265] 1185
Failure Code [CA2266] 1187
Failure Code [CA2271] 1189
Failure Code [CA2272] 1191
Failure Code [CA2349] 1193
Failure Code [CA2353] 1195
Failure Code [CA2357] 1197
Failure Code [CA2381] 1198
Failure Code [CA2382] 1200
Failure Code [CA2383] 1202
Failure Code [CA2386] 1204
Failure Code [CA2387] 1206
Troubleshooting Flowchart 1210
Failure Code [CA2555] 1211
Failure Code [CA2556] 1213
Failure Code [CA2637] 1215
Failure Code [CA2639] 1217
Failure Code [CA2732] 1219
Failure Code [CA2733] 1221
Failure Code [CA2741] 1223
Failure Code [CA2765] 1224
Failure Code [CA2771] 1225
Failure Code [CA2777] 1231
Failure Code [CA2878] 1234
Failure Code [CA2881] 1237
Failure Code [CA2976] 1240
Failure Code [CA3133] 1242
Failure Code [CA3134] 1244
Failure Code [CA3135] 1246
Failure Code [CA3142] 1249
Failure Code [CA3143] 1250
Failure Code [CA3144] 1251
Failure Code [CA3146] 1253
Failure Code [CA3147] 1254
Failure Code [CA3148] 1255
Failure Code [CA3151] 1257
Failure Code [CA3165] 1262
Failure Code [CA3167] 1265
Failure Code [CA3229] 1269
Failure Code [CA3231] 1272
Failure Code [CA3232] 1275
Failure Code [CA3235] 1280
Failure Code [CA3239] 1282
Failure Code [CA3241] 1285
Failure Code [CA3242] 1288
Failure Code [CA3251] 1291
Failure Code [CA3253] 1294
Failure Code [CA3254] 1300
Failure Code [CA3255] 1304
Failure Code [CA3256] 1307
Failure Code [CA3311] 1310
Failure Code [CA3312] 1313
Failure Code [CA3313] 1316
Failure Code [CA3314] 1317
Failure Code [CA3315] 1318
Failure Code [CA3316] 1321
Failure Code [CA3317] 1322
Failure Code [CA3318] 1323
Failure Code [CA3319] 1326
Failure Code [CA3321] 1327
Failure Code [CA3322] 1328
Failure Code [CA3419] 1331
Failure Code [CA3421] 1333
Failure Code [CA3497] 1335
Failure Code [CA3498] 1336
Failure Code [CA3543] 1337
Failure Code [CA3545] 1342
Failure Code [CA3547] 1344
Failure Code [CA3558] 1345
Failure Code [CA3559] 1347
Failure Code [CA3562] 1349
Failure Code [CA3563] 1351
Failure Code [CA3567] 1354
Failure Code [CA3568] 1357
Failure Code [CA3571] 1361
Failure Code [CA3572] 1363
Failure Code [CA3574] 1365
Failure Code [CA3575] 1368
Failure Code [CA3577] 1370
Failure Code [CA3578] 1372
Failure Code [CA3582] 1374
Failure Code [CA3583] 1380
Failure Code [CA3596] 1382
Failure Code [CA3649] 1385
Failure Code [CA3681] 1388
Failure Code [CA3682] 1393
Failure Code [CA3713] 1399
Failure Code [CA3717] 1402
Failure Code [CA3718] 1403
Failure Code [CA3725] 1404
Failure Code [CA3748] 1407
Failure Code [CA3751] 1409
Failure Code [CA3755] 1411
Failure Code [CA3866] 1413
Failure Code [CA3867] 1417
Failure Code [CA3868] 1420
Failure Code [CA3899] 1424
Failure Code [CA3911] 1427
Failure Code [CA3912] 1431
Failure Code [CA3932] 1433
Failure Code [CA3933] 1435
Failure Code [CA3934] 1437
Failure Code [CA3935] 1440
Failure Code [CA3936] 1442
Failure Code [CA4151] 1444
Failure Code [CA4152] 1448
Failure Code [CA4155] 1452
Failure Code [CA4156] 1454
Failure Code [CA4157] 1457
Failure Code [CA4158] 1459
Failure Code [CA4159] 1461
Failure Code [CA4161] 1463
Failure Code [CA4162] 1466
Failure Code [CA4163] 1469
Failure Code [CA4164] 1471
Failure Code [CA4165] 1473
Failure Code [CA4166] 1475
Failure Code [CA4168] 1478
Failure Code [CA4169] 1483
Failure Code [CA4171] 1488
Failure Code [CA4249] 1493
Failure Code [CA4251] 1497
Failure Code [CA4259] 1501
Failure Code [CA4261] 1504
Failure Code [CA4277] 1507
Failure Code [CA4281] 1510
Failure Code [CA4459] 1513
Failure Code [CA4461] 1515
Failure Code [CA4658] 1518
Failure Code [CA4731] 1522
Failure Code [CA4732] 1523
Failure Code [CA4739] 1524
Failure Code [CA4768] 1525
Failure Code [CA4769] 1527
Failure Code [CA4842] 1529
Failure Code [CA4952] 1533
Failure Code [CA5115] 1535
Failure Code [CA5179] 1538
Failure Code [CA5181] 1540
Failure Code [CA5383] 1542
Failure Code [D110KB] 1544
Failure Code [D163KB] 1546
Failure Code [D195KA] 1548
Failure Code [D195KB] 1550
Failure Code [D19JKZ] 1552
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1554
Failure Code [D811MC] (Machine with Gateway Function Controller) 1555
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1556
Failure Code [D862KA] (Machine with Gateway Function Controller) 1557
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1559
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1561
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1564
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1566
Failure Code [D8AQKR] 1568
Failure Code [D8G1KT] (Machine with Gateway Function Controller) 1572
Failure Code [D8G6KT] (Machine with Gateway Function Controller) 1573
Failure Code [DA20MC] 1574
Failure Code [DA22KK] 1575
Failure Code [DA25KP] 1577
Failure Code [DA26KP] 1579
Failure Code [DA29KQ] 1582
Failure Code [DA2LKA] 1584
Failure Code [DA2LKB] 1586
Failure Code [DA2QKR] 1588
Failure Code [DA2RKR] 1593
Failure Code [DAF0KM] 1598
Failure Code [DAF0MB] 1599
Failure Code [DAF0MC] 1600
Failure Code [DAF8KB] 1601
Failure Code [DAF9KQ] 1602
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1603
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1604
Failure Code [DAFLKA] 1605
Failure Code [DAFLKB] 1607
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1609
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1613
Failure Code [DAZ9KQ] 1617
Failure Code [DAZQKR] 1618
Failure Code [DB2QKR] 1622
Failure Code [DB2RKR] 1627
Failure Code [DBP0KM] 1632
Failure Code [DBP0KT] 1633
Failure Code [DBPQKR] 1634
Failure Code [DDNRKA] 1639
Failure Code [DDNRKY] 1641
Failure Code [DDNS00] 1643
Failure Code [DGE5KB] 1645
Failure Code [DGH2KA] 1646
Failure Code [DGH2KB] 1648
Failure Code [DHA4KA] 1650
Failure Code [DHAAMA] 1652
Failure Code [DHACMA] 1654
Failure Code [DHPAMA] 1656
Failure Code [DHPBMA] 1658
Failure Code [DHS3MA] 1660
Failure Code [DHS4MA] 1663
Failure Code [DHS8MA] 1666
Failure Code [DHS9MA] 1669
Failure Code [DHSAMA] 1672
Failure Code [DHSBMA] 1675
Failure Code [DHSCMA] 1678
Failure Code [DHSDMA] 1681
Failure Code [DHSFMA] 1684
Failure Code [DHSGMA] 1687
Failure Code [DHSHMA] 1690
Failure Code [DHSJMA] 1693
Failure Code [DKULKA] 1696
Failure Code [DKULKB] 1698
Failure Code [DKULKY] 1700
Failure Code [DLM3KA] 1702
Failure Code [DLM3KB] 1704
Failure Code [DLM3MB] 1706
Failure Code [DR10KA] 1707
Failure Code [DR12KA] 1710
Failure Code [DR20KA] 1712
Failure Code [DR21KX] 1714
Failure Code [DR30KA] 1716
Failure Code [DR31KX] 1718
Failure Code [DR40KA] 1720
Failure Code [DUMBKA] 1722
Failure Code [DUMBKB] 1724
Failure Code [DV20KB] 1726
Failure Code [DW43KA] 1727
Failure Code [DW43KB] 1729
Failure Code [DW43KY] 1731
Failure Code [DW45KA] 1732
Failure Code [DW45KB] 1735
Failure Code [DW45KY] 1738
Failure Code [DW48KA] 1740
Failure Code [DW48KB] 1742
Failure Code [DW48KY] 1744
Failure Code [DW4CKY] 1745
Failure Code [DW4XKA] 1747
Failure Code [DW4XKB] 1749
Failure Code [DW4XKY] 1751
Failure Code [DW7BKA] 1752
Failure Code [DW7BKB] 1754
Failure Code [DW7BKY] 1756
Failure Code [DWK0KA] 1757
Failure Code [DWK0KB] 1759
Failure Code [DWK0KY] 1761
Failure Code [DWK2KA] 1762
Failure Code [DWK2KB] 1764
Failure Code [DWK2KY] 1766
Failure Code [DWK8KA] 1767
Failure Code [DWK8KB] 1769
Failure Code [DWK8KY] 1771
Failure Code [DX16KA] 1772
Failure Code [DX16KB] 1774
Failure Code [DXA2KA] 1775
Failure Code [DXA2KB] 1778
Failure Code [DXA3KA] 1780
Failure Code [DXA3KB] 1783
Failure Code [DY20KA] 1785
Failure Code [DY20MA] 1787
Failure Code [DY2CKB] 1789
Failure Code [DY2DKB] 1791
Failure Code [DY2EKB] 1793
Failure Code [DY2FMA] 1795
Failure Code [DY2GKM] 1797
Failure Code [F311KA] 1799
Failure Code [F311KB] 1801
Failure Code [F312KA] 1803
Failure Code [F312KB] 1805
Failure Code [F313KA] 1807
Failure Code [F313KB] 1809
Failure Code [F314KA] 1812
Failure Code [F314KB] 1814
Failure Code [F315KB] 1816
Failure Code [F315KY] 1818
Failure Code [F316KB] 1820
Failure Code [F316KY] 1822
Failure Code [F318KB] 1824
Failure Code [F318KY] 1827
Failure Code [F31AKB] 1829
Failure Code [F31AKY] 1831
Failure Code [F31BKB] 1833
Failure Code [F31BKY] 1835
Failure Code [F31CKB] 1837
Failure Code [F31CKY] 1839
Failure Code [F31DKB] 1841
Failure Code [F31DKY] 1843
Failure Code [F31EKB] 1845
Failure Code [F31EKY] 1847
Troubleshooting of Electrical System (E-Mode) 1849
E-1 Engine Does Not Start (Engine Does Not Crank) 1849
E-2 Manual Preheating System Does Not Operate 1855
E-3 Automatic Preheating System Does Not Operate 1858
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1860
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1862
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1865
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1866
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1867
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1868
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1869
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1870
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1871
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1872
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1873
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation 1874
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum 1875
E-17 Display of Fuel Gauge is Different from Actual Fuel Level 1877
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1878
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1879
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1880
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1882
E-22 Some Areas of Machine Monitor Screen are Not Shown 1883
E-23 Function Switch Does Not Operate 1884
E-24 Automatic Warm-up System Does Not Work (in Cold Weather) 1885
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1886
E-26 Auto-Decelerator is Not Operated or Canceled with Lever 1887
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1888
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1889
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1890
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1891
E-31 Alarm Buzzer Cannot be Canceled 1892
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position 1893
E-33 Service Mode Cannot be Selected 1894
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1895
E-35 All Work Equipment, Swing and Travel Do Not Lock 1898
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1900
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1903
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor 1905
E-39 One-Touch Power Maximizing Function is Not Cancelled 1907
E-40 Alarm Does Not Sound During Travel 1908
E-41 Alarm Does Not Stop When Machine Stops 1910
E-42 Horn Does Not Sound 1911
E-43 Horn Does Not Stop 1914
E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1916
E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1917
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated 1919
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1920
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1921
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function 1922
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function 1923
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1924
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1925
E-53 “Swing” is Not Shown Correctly with Monitoring Function 1926
E-54 “Travel” is Not Shown Correctly with Monitoring Function 1927
E-55 Service is Not Shown Correctly with Monitoring Function 1928
E-56 KOMTRAX System Does Not Operate Correctly 1930
E-57 Machine Push-Up Function is Not Canceled 1931
E-58 Machine Push-up Function Does Not Operate 1933
E-59 Step Light Does Not Come On 1934
E-60 Step Light Does Not Go Out 1936
E-61 Boom Shockless Function Cannot be Canceled 1938
E-62 Boom Shockless Function Does Not Work 1940
E-63 Electric Grease Gun Does Not Work 1941
E-64 Electric Grease Gun Does Not Stop 1943
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1944
H-1 All Work Equipment, Swing and Travel Do Not Work 1944
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1945
H-3 Unusual Noise is Heard from Around Hydraulic Pump 1947
H-4 Engine Speed Drops Largely or Engine Stops 1948
H-5 Travel Speed or Power is Low 1949
H-6 Auto-Deceleration Function Cannot be Canceled 1950
H-7 Speed or Power of Boom is Low 1951
H-8 Arm Speed or Power is Low 1953
H-9 Bucket Speed or Power is Low 1954
H-10 Work Equipment Does Not Move in Single Operation 1955
H-11 Hydraulic Drift of Boom is Large 1956
H-12 Hydraulic Drift of Arm is Large 1957
H-13 Hydraulic Drift of Bucket is Large 1958
H-14 Time Lag of Work Equipment is Large 1959
H-15 One-Touch Power Maximizing Function Does Not Operate 1960
H-16 Machine Push-Up Function Does Not Operate 1961
H-17 Machine Does Not Travel Straight 1962
H-18 Speed of Boom and Bucket is Slow at Mixed Operation of Arm, Boom and Bucket 1963
H-19 Speed of Boom, Arm, Swing and Travel is Slow at Mixed Operation of Bucket, Boom and Arm 1964
H-20 Swing Speed is Slow at Mixed Operation of Arm and Swing 1965
H-21 Travel Deviation is Large at Start of Traveling 1966
H-22 Travel Deviation is Large at Mixed Operation 1968
H-23 One of Tracks Does Not Run 1969
H-24 Travel Speed Does Not Change 1971
H-25 Upper Structure Does Not Swing to Right and Left 1972
H-26 Upper Structure Swings Only to Right or Left 1973
H-27 Swing Acceleration or Swing Speed is Low in Right and Left Directions 1974
H-28 Swing Acceleration or Swing Speed is Low in Only One Direction 1975
H-29 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1976
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1977
H-31 Shock is Large When Upper Structure Stops Swing Operation 1978
H-32 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation 1979
H-33 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1980
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1981
H-35 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1982
H-36 Unusual Noise is Heard from Around Fan 1983
Troubleshooting of Engine (S-Mode) 1984
Information Shown in Troubleshooting Table (S-Mode) 1984
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1985
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1986
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1987
S-4 Engine Startability is Unsatisfactory 1988
S-5 Engine Does Not Pick Up Smoothly 1990
S-6 Engine Stops During Operation 1992
S-7 Engine Runs Rough or is Not Stable 1994
S-8 Engine Lacks Power 1995
S-9 KDPF Becomes Clogged in a Short Time 1997
S-10 Engine Oil Consumption is Excessive 1999
S-11 Oil Becomes Dirty Quickly 2000
S-12 Fuel Consumption is Excessive 2001
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2002
S-14 Oil Pressure Drops 2003
S-15 Fuel Mixes Into Engine Oil 2005
S-16 Water Mixes Into Engine Oil (Milky) 2006
S-17 Coolant Temperature Increases Too High (Overheating) 2007
S-18 Unusual Noise is Heard 2008
S-19 Vibration is Excessive 2009
S-20 Air Cannot be Bled from Fuel Circuit 2010
S-21 Active Regeneration is Done Frequently 2011
S-22 Active Regeneration Continues Long 2013
S-23 White Smoke is Exhausted During Active Regeneration 2014
S-24 DEF Consumption is Excessive 2015
S-25 There is Unusual Smell (Irritating Odor) 2017
S-26 Foreign Materials Enter DEF (DEF Increases) 2018
50 Disassembly and Assembly 2019
Table of Contents 2020
Precautions Before Work 2026
Related Information on Disassembly and Assembly 2027
How to Read This Manual 2027
Coating Materials List 2029
Special Tool List 2034
Sketches of Special Tools 2051
Engine and Cooling System 2058
Remove and Install Supply Pump Assembly 2058
How to Remove Supply Pump Assembly 2058
How to Install Supply Pump Assembly 2061
Remove and Install Injector Assembly 2066
How to Remove Injector Assembly 2066
How to Install Injector Assembly 2071
Remove and Install Fuel Doser Assembly 2080
How to Remove Fuel Doser Assembly 2080
How to Install Fuel Doser Assembly 2081
Remove and Install Cylinder Head Assembly 2083
How to Remove Cylinder Head Assembly 2084
How to Install Cylinder Head Assembly 2094
Remove and Install EGR Valve Assembly 2111
How to Remove EGR Valve Assembly 2111
How to Install EGR Valve Assembly 2113
Remove and Install EGR Cooler Assembly 2115
How to Remove EGR Cooler Assembly 2115
How to Install EGR Cooler Assembly 2118
Remove and Install Starter Assembly 2122
How to Remove Starting Motor Assembly 2122
How to Install Starting Motor Assembly 2123
Remove and Install Alternator Belt 2124
How to Remove Alternator Belt 2124
How to Install Alternator Belt 2125
Remove and Install Radiator Assembly 2127
How to Remove Radiator Assembly 2127
How to Install Radiator Assembly 2130
Remove and Install Hydraulic Oil Cooler Assembly 2134
How to Remove Hydraulic Oil Cooler Assembly 2134
How to Install Hydraulic Oil Cooler Assembly 2137
Remove and Install Aftercooler Assembly 2141
How to Remove Aftercooler Assembly 2141
How to Install Aftercooler Assembly 2143
Remove and Install Cooling Fan Motor Assembly 2146
How to Remove Cooling Fan Motor Assembly 2146
How to Install Cooling Fan Motor Assembly 2155
Remove and Install Engine, PTO, and Hydraulic Pump Assembly 2164
How to Remove Engine PTO and Hydraulic Assembly 2164
How to Install Engine PTO and Hydraulic Assembly 2175
Remove and Install Engine Front Oil Seal 2186
How to Remove Engine Front Oil Seal 2186
How to Install Engine Front Oil Seal 2187
Remove and Install Engine Rear Oil Seal 2190
How to Remove Engine Rear Oil Seal 2190
How to Install Engine Rear Oil Seal 2192
Remove and Install Engine Hood Assembly 2198
How to Remove Engine Hood Assembly 2198
How to Install Engine Hood Assembly 2203
Remove and Install Fuel Tank Assembly 2208
How to Remove Fuel Tank Assembly 2208
How to Install Fuel Tank Assembly 2211
Remove and Install DEF Tank Assembly 2215
How to Remove DEF Tank Assembly 2216
How to Install DEF Tank Assembly 2222
Remove and Install DEF Tank Sensor Flange Assembly 2227
How to Remove DEF Tank Sensor Flange Assembly 2227
How to Install DEF Tank Sensor Flange Assembly 2228
Remove and Install DEF Tank Sensor 2230
How to Remove DEF Tank Sensor 2230
How to Install DEF Tank Sensor 2231
Remove and Install DEF Tank Strainer 2237
How to Remove DEF Tank Strainer 2237
How to Install DEF Tank Strainer 2237
Remove and Install DEF Tank Filler Port Filter 2238
How to Remove DEF Tank Filler Port Filter 2238
How to Install DEF Tank Filler Port Filter 2240
Remove and Install KDPF Assembly 2243
How to Remove KDPF Assembly 2243
How to Install KDPF Assembly 2247
Disassemble and Assemble KDPF Assembly 2256
How to Disassemble KDPF Assembly 2257
How to Assemble KDPF Assembly 2261
Remove and Install SCR Assembly 2266
How to Remove SCR Assembly 2266
How to Install SCR Assembly 2268
Remove and Install KDPF and SCR Assembly 2272
How to Remove KDPF and SCR Assembly 2273
How to Install KDPF and SCR Assembly 2279
Remove and Install Bellows Pipe Assembly 2291
How to Remove Bellows Pipe Assembly 2291
How to Install Bellows Pipe Assembly 2293
Remove and Install KCCV Assembly 2301
How to Remove KCCV Assembly 2301
How to Install KCCV Assembly 2302
Remove and Install DEF Mixing Tube 2305
How to Remove DEF Mixing Tube 2305
How to Install DEF Mixing Tube 2310
Remove and Install DEF Injector 2317
How to Remove DEF Injector 2317
How to Install DEF Injector 2320
Remove and Install DEF Pump 2324
How to Remove DEF Pump 2324
How to Install DEF Pump 2327
Remove and Install DEF Hose 2330
How to Remove DEF Hose 2331
How to Install DEF Hose 2339
Remove and Install Air Cleaner Assembly 2345
How to Remove Air Cleaner Assembly 2345
How to Install Air Cleaner Assembly 2346
Remove and Install Air Conditioner Compressor Assembly 2347
How to Remove Air Conditioner Compressor Assembly 2347
How to Install Air Conditioner Compressor Assembly 2348
Remove and Install Air Conditioner Condenser Assembly 2350
How to Remove Air Conditioner Condenser Assembly 2350
How to Install Air Conditioner Condenser Assembly 2351
Power Train 2352
Disassemble and Assemble PTO Assembly 2352
How to Disassemble PTO Assembly 2352
How to Assemble PTO Assembly 2353
Remove and Install PTO Assembly 2356
How to Remove PTO Assembly 2356
How to Install PTO Assembly 2357
Remove and Install Travel Motor and Final Drive Assembly 2360
How to Remove Travel Motor and Final Drive Assembly 2360
How to Install Travel Motor and Final Drive Assembly 2361
Disassemble and Assemble Final Drive Assembly 2362
How to Disassemble Final Drive Assembly 2363
How to Assemble Final Drive Assembly 2368
Remove and Install Swing Motor and Swing Machinery Assembly 2377
How to Remove Swing Motor and Swing Machinery Assembly 2377
How to Install Swing Motor and Swing Machinery Assembly 2378
Disassemble and Assemble Swing Machinery Assembly 2380
How to Disassemble Swing Machinery Assembly 2380
How to Assemble Swing Machinery Assembly 2384
Remove and Install Swing Circle Assembly 2389
How to Remove Swing Circle Assembly 2389
How to Install Swing Circle Assembly 2390
Undercarriage and Frame 2391
Disassemble and Assemble Recoil Spring Assembly 2391
How to Disassemble Recoil Spring Assembly 2391
How to Assemble Recoil Spring Assembly 2392
Remove and Install Track Roller Assembly 2394
How to Remove Track Roller Assembly 2394
How to Install Track Roller Assembly 2395
Remove and Install Carrier Roller Assembly 2396
How to Remove Carrier Roller Assembly 2396
How to Install Carrier Roller Assembly 2396
Disassemble and Assemble One Track Link Assembly in Field 2398
How to Disassemble One Track Link Assembly in Field 2400
How to Assemble One Track Link Assembly in Field 2401
Separate and Connect Track Assembly 2404
How to Separate Track Assembly 2404
How to Install Track Assembly 2405
Remove and Install Idler and Idler Cushion Assembly 2407
How to Remove Idler and Idler Cushion Assembly 2407
How to Install Idler and Idler Cushion Assembly 2408
Disassemble and Assemble Idler Assembly 2409
How to Disassemble Idler Assembly 2409
How to Assemble Idler Assembly 2410
Disassemble and Assemble Idler Cushion Assembly 2413
How to Disassemble Idler Cushion Assembly 2413
How to Assemble Idler Cushion Assembly 2414
Disassemble and Assemble Track Roller Assembly 2416
How to Disassemble Track Roller Assembly 2416
How to Assemble Track Roller Assembly 2417
Disassemble and Assemble Carrier Roller Assembly 2420
How to Disassemble Carrier Roller Assembly 2420
How to Assemble Carrier Roller Assembly 2421
Remove and Install Revolving Frame Assembly 2423
How to Remove Revolving Frame Assembly 2423
How to Install Revolving Frame Assembly 2424
Remove and Install Counterweight Assembly 2426
How to Remove Counterweight Assembly 2426
How to Install Counterweight Assembly 2426
Hydraulic System 2429
Remove and Install Center Swivel Joint Assembly 2429
How to Remove Center Swivel Joint Assembly 2429
How to Install Center Swivel Joint Assembly 2430
Disassemble and Assemble Center Swivel Joint Assembly 2431
How to Disassemble Center Swivel Joint Assembly 2432
How to Assemble Center Swivel Joint Assembly 2433
Remove and Install Hydraulic Tank Assembly 2434
How to Remove Hydraulic Tank Assembly 2434
How to Install Hydraulic Tank Assembly 2436
Remove and Install Hydraulic Pump Assembly 2439
How to Remove Hydraulic Pump Assembly 2439
How to Install Hydraulic Pump Assembly 2441
Remove and Install Control Valve Assembly 2447
How to Remove Control Valve Assembly 2447
How to Install Control Valve Assembly 2450
Remove and Install Swing Motor Assembly 2454
How to Remove Swing Motor Assembly 2454
How to Install Swing Motor Assembly 2455
Disassemble and Assemble Work Equipment PPC Valve Assembly 2456
How to Disassemble Work Equipment PPC Valve Assembly 2456
How to Assemble Work Equipment PPC Valve Assembly 2457
Disassemble and Assemble Travel PPC Valve Assembly 2459
How to Disassemble Travel PPC Valve Assembly 2459
How to Assemble Travel PPC Valve Assembly 2460
Disassemble and Assemble Grease Gun Assembly 2462
How to Disassemble Grease Gun Assembly 2462
How to Assemble Grease Gun Assembly 2462
Work Equipment 2463
Remove and Install Bucket Cylinder Assembly 2463
How to Remove Bucket Cylinder Assembly 2463
How to Install Bucket Cylinder Assembly 2464
Remove and Install Arm Cylinder Assembly 2466
How to Remove Arm Cylinder Assembly 2466
How to Install Arm Cylinder Assembly 2467
Remove and Install Boom Cylinder Assembly 2469
How to Remove Boom Cylinder Assembly 2469
How to Install Boom Cylinder Assembly 2470
Remove and Install Bucket Assembly 2472
How to Remove Bucket Assembly 2472
How to Install Bucket Assembly 2473
Remove and Install Arm Assembly 2474
How to Remove Arm Assembly 2474
How to Install Arm Assembly 2476
Remove and Install Boom Assembly 2478
How to Remove Boom Assembly 2478
How to Install Boom Assembly 2479
Remove and Install Work Equipment Assembly 2481
How to Remove Work Equipment Assembly 2481
How to Install Work Equipment Assembly 2483
Disassemble and Assemble Anti-Drop Valve Assembly 2485
How to Disassemble Anti-Drop Valve Assembly 2485
How to Assemble Anti-Drop Valve Assembly 2485
Disassemble and Assemble Work Equipment Cylinder Assembly 2486
How to Disassemble Work Equipment Cylinder Assembly 2487
How to Assemble Work Equipment Cylinder Assembly 2489
CAB Related Parts 2494
Remove and Install Operator Cab Assembly 2494
How to Remove Operator Cab Assembly 2494
How to Install Operator Cab Assembly 2501
Remove and Install Operator Cab Glass (Adhered Glass) 2510
How to Remove Operator Cab Glass (Adhered Glass) 2512
How to Install Operator Cab Glass (Adhered Glass) 2512
Remove and Install Front Window Assembly 2522
How to Remove Front Window Assembly 2522
How to Install Front Window Assembly 2525
Remove and Install Floor Frame Assembly 2531
How to Remove Floor Frame Assembly 2531
How to Install Floor Frame Assembly 2534
Remove and Install Air Conditioner Unit Assembly 2539
How to Remove Air Conditioner Unit Assembly 2539
How to Install Air Conditioner Unit Assembly 2544
Remove and Install Operator Seat 2551
How to Remove Operator Seat 2551
How to Install Operator Seat 2553
How to Remove and Install Seat Belt 2556
How to Remove Seat Belt 2556
How to Install Seatbelt 2556
Remove and Install Work Equipment Control Lever Assembly 2558
How to Remove Work Equipment Control Lever Assembly 2558
How to Install Work Equipment Control Lever Assembly 2564
Remove and Install Front Wiper Assembly 2572
How to Remove Front Wiper Assembly 2572
How to Install Front Wiper Assembly 2577
Electrical System 2586
Remove and Install Engine Controller Assembly 2586
How to Remove Engine Controller Assembly 2586
How to Install Engine Controller Assembly 2587
Remove and Install Pump Controller Assembly 2590
How to Remove Pump Controller Assembly 2590
How to Install Pump Controller Assembly 2592
Remove and Install KomVision Controller Assembly 2595
How to Remove KomVision Controller Assembly 2595
How to Install KomVision Controller Assembly 2596
Remove and Install Machine Monitor Assembly 2598
How to Remove Machine Monitor Assembly 2598
How to Install Machine Monitor Assembly 2600
Remove and Install Mass Air Flow and Temperature Sensor 2604
How to Remove Mass Air Flow and Temperature Sensor 2604
How to Install Mass Air Flow and Temperature Sensor 2605
Remove and Install KCCV Crankcase Pressure Sensor 2606
How to Remove KCCV Crankcase Pressure Sensor 2606
How to Install KCCV Crankcase Pressure Sensor 2607
Remove and Install SCR Temperature Sensor 2609
How to Remove SCR Temperature Sensor 2609
How to Install SCR Temperature Sensor 2611
Remove and Install KomVision Camera 2613
How to Remove KomVision Camera 2613
How to Install KomVision Camera 2616
Remove and Install KOMTRAX Terminal Assembly 2619
How to Remove KOMTRAX Terminal Assembly 2619
How to Install KOMTRAX Terminal Assembly 2621
Remove and Install Gateway Function Controller Assembly 2623
How to Remove Gateway Function Controller Assembly 2623
How to Install Gateway Function Controller Assembly 2628
Remove and Install Communication Terminal Wiring Harness 2633
How to Remove Communication Terminal Wiring Harness 2633
How to Install Communication Terminal Wiring Harness 2641
Remove and Install Communication Terminal 2650
How to Remove Communication Terminal 2650
How to Install Communication Terminal 2652
60 Maintenance Standard 2655
Table of Contents 2656
Engine and Cooling System 2657
Maintenance Standard for Engine Mount 2657
Maintenance Standard for PTO 2659
Maintenance Standard for Cooling System 2660
Maintenance Standard for Cooling Fan Pump 2661
Maintenance Standard for Servo Valve 2662
Maintenance Standard for Cooling Fan Motor 2663
Power Train 2664
Maintenance Standard for Swing Circle 2664
Maintenance Standard for Swing Machinery 2665
Maintenance Standard for Final Drive 2667
Maintenance Standard for Sprocket 2669
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2670
Undercarriage and Frame 2671
Maintenance Standard for Track Frame and Idler Cushion 2671
Maintenance Standard for Idler 2673
Maintenance Standard for Track Roller 2675
Maintenance Standard for Carrier Roller 2676
Maintenance Standard for Track Shoes 2677
Maintenance Standard for Double Shoes 2680
Maintenance Standard for Triple Shoes 2681
Hydraulic System 2682
Maintenance Standard for Main Pump 2682
Maintenance Standard for Main Pump Servo Valve 2684
Maintenance Standard for Main Pump TVC Valve 2686
Maintenance Standard for Main Pump CO and NC Valve 2687
Maintenance Standard for Swing Motor 2688
Maintenance Standard for Travel Motor 2689
Maintenance Standard for Control Valve 2691
Maintenance Standard for Travel Shuttle Valve of Control Valve 2697
Maintenance Standard for Variable Back Pressure Valve 2698
Maintenance Standard for Work Equipment and Swing PPC Valve 2699
Maintenance Standard for Travel PPC Valve 2702
Maintenance Standard for 1st-Line Attachment PPC Valve 2705
Maintenance Standard for Solenoid Valve 2707
Maintenance Standard for Center Swivel Joint 2708
Work Equipment 2709
Maintenance Standard for Work Equipment Linkage 2709
Dimensions of Arm 2714
Dimensions of Bucket 2716
Maintenance Standard for Boom Cylinder 2718
Maintenance Standard for Arm Cylinder 2719
Maintenance Standard for Bucket Cylinder 2720
80 Appendix 2721
Table of Contents 2722
Precautions Before Work 2724
Air Conditioner System 2725
Precautions for Refrigerant 2725
Air Conditioner Component 2726
Specifications of Air Conditioner 2728
Structure and Function of Refrigeration Cycle 2729
Outline of Refrigeration Cycle 2730
Component Parts of Air Conditioner System 2732
Air Conditioner Unit 2732
Configuration Diagram of Air Conditioner Unit 2732
Function of Air Conditioner Unit 2734
Component Parts of Air Conditioner Unit 2736
Function of Evaporator as Air Conditioner Unit Component 2737
Function of Heater Core as Air Conditioner Unit Component 2737
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2737
Function of Servo Motor as Air Conditioner Unit Component 2737
Structure of Expansion Valve as Air Conditioner Unit Component 2738
Function of Expansion Valve as Air Conditioner Unit Component 2738
Operate Expansion Valve as Air Conditioner Unit Component 2738
Function of Dual Pressure Switch 2739
Air Conditioner Controller 2740
Structure of Air Conditioner Controller 2740
Compressor 2741
Structure of Compressor 2741
Specifications of Compressor 2741
Function of Compressor 2741
Condenser 2742
Structure of Condenser 2742
Specifications of Condenser 2742
Function of Condenser 2742
Receiver Drier 2743
Structure of Receiver Dryer 2743
Specifications of Receiver Dryer 2743
Function of Receiver Dryer 2743
Air Conditioner Related Sensors 2744
Structure of Sunlight Sensor 2744
Function of Sunlight Sensor 2744
Structure of Outside Temperature Sensor 2744
Function of Outside Air Temperature Sensor 2744
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2746
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2748
System Diagram of Air Conditioner 2750
Input and Output Signals of Air Conditioner Controller 2751
Function of Air Conditioner Controller 2752
Locations of Air Conditioner Parts and Layout of Connectors 2753
Examine Air Leakage (Duct) 2757
How to Examine Air Leakage (Duct) 2757
Examine Air Conditioner with Self-Diagnosis Function 2759
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2760
Examine Vent (Mode) Changeover 2761
How to Examine Vent (Mode) Changeover 2761
Examine Fresh/Recirc Air Changeover 2763
How to Examine Fresh/Recirc Air Changeover 2763
Examine Sunlight Sensor 2764
How to Examine Sunlight Sensor 2764
Examine Refrigerant (Dual) Pressure Switch 2765
How to Examine Refrigerant (Dual) Pressure Switch 2765
Examine Relay 2766
How to Examine Relay 2766
Air Conditioner Troubleshooting Chart 1 2767
Air Conditioner Troubleshooting Chart 2 2768
Information Shown in Troubleshooting Table 2771
Failure Code [879AKA] 2772
Failure Code [879AKB] 2773
Failure Code [879BKA] 2774
Failure Code [879BKB] 2776
Failure Code [879CKA] 2778
Failure Code [879CKB] 2779
Failure Code [879DKZ] 2780
Failure Code [879EMC] 2782
Failure Code [879FMC] 2783
Failure Code [879GKX] 2784
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2786
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2788
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2791
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2793
Troubleshooting by Gauge Pressure 2795
Connect Service Tool 2798
How to Connect Service Tool 2798
Precautions for Disconnection and Connection of Air Conditioner Piping 2800
Handle Compressor Oil 2802
90 Circuit Diagrams 2805
Table of Contents 2806
Hydraulic Circuit Diagram 2807
Symbols Used in Hydraulic Circuit Diagram 2807
Hydraulic Circuit Diagram (Oceania Spec) 2811
Hydraulic Circuit Diagram (1/3) (Turkey Spec) 2813
Hydraulic Circuit Diagram (2/3) (Turkey Spec) 2815
Hydraulic Circuit Diagram (3/3) (Turkey Spec) 2817
Electrical Circuit Diagram 2819
Symbols Used in Electric Circuit Diagram 2819
Electrical Circuit Diagram (1/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2823
Electrical Circuit Diagram (2/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2825
Electrical Circuit Diagram (3/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2827
Electrical Circuit Diagram (4/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2829
Electrical Circuit Diagram (5/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2831
Electrical Circuit Diagram (6/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2833
Electrical Circuit Diagram (7/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2835
Electrical Circuit Diagram (8/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2837
Electrical Circuit Diagram (9/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2839
Electrical Circuit Diagram (10/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2841
Electrical Circuit Diagram (11/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2843
Electrical Circuit Diagram (12/12) (Machine with KOMTRAX Terminal) (Oceania Spec) 2845
Electrical Circuit Diagram (1/13) (Machine with Gateway Function Controller) (Oceania Spec) 2847
Electrical Circuit Diagram (2/13) (Machine with Gateway Function Controller) (Oceania Spec) 2849
Electrical Circuit Diagram (3/13) (Machine with Gateway Function Controller) (Oceania Spec) 2851
Electrical Circuit Diagram (4/13) (Machine with Gateway Function Controller) (Oceania Spec) 2853
Electrical Circuit Diagram (5/13) (Machine with Gateway Function Controller) (Oceania Spec) 2855
Electrical Circuit Diagram (6/13) (Machine with Gateway Function Controller) (Oceania Spec) 2857
Electrical Circuit Diagram (7/13) (Machine with Gateway Function Controller) (Oceania Spec) 2859
Electrical Circuit Diagram (8/13) (Machine with Gateway Function Controller) (Oceania Spec) 2861
Electrical Circuit Diagram (9/13) (Machine with Gateway Function Controller) (Oceania Spec) 2863
Electrical Circuit Diagram (10/13) (Machine with Gateway Function Controller) (Oceania Spec) 2865
Electrical Circuit Diagram (11/13) (Machine with Gateway Function Controller) (Oceania Spec) 2867
Electrical Circuit Diagram (12/13) (Machine with Gateway Function Controller) (Oceania Spec) 2869
Electrical Circuit Diagram (13/13) (Machine with Gateway Function Controller) (Oceania Spec) 2871
Electrical Circuit Diagram (1/13) (Turkey Spec) 2873
Electrical Circuit Diagram (2/13) (Turkey Spec) 2875
Electrical Circuit Diagram (3/13) (Turkey Spec) 2877
Electrical Circuit Diagram (4/13) (Turkey Spec) 2879
Electrical Circuit Diagram (5/13) (Turkey Spec) 2881
Electrical Circuit Diagram (6/13) (Turkey Spec) 2883
Electrical Circuit Diagram (7/13) (Turkey Spec) 2885
Electrical Circuit Diagram (8/13) (Turkey Spec) 2887
Electrical Circuit Diagram (9/13) (Turkey Spec) 2889
Electrical Circuit Diagram (10/13) (Turkey Spec) 2891
Electrical Circuit Diagram (11/13) (Turkey Spec) 2893
Electrical Circuit Diagram (12/13) (Turkey Spec) 2895
Electrical Circuit Diagram (13/13) (Turkey Spec) 2897
Index 2899

S.V  21/12/24