Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06737-11 PDF

Description

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06737-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06737-11 – PDF DOWNLOAD

Language : English
Pages :2868
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06737-11 – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06737-11 – PDF DOWNLOAD

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC240LC-11 93
Working Range Drawings 95
Working Range: PC240LC-11 95
Specifications 96
Specifications: PC240LC-11 96
Weight Table 99
Weight Table: PC240LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 108
Urea SCR System Diagram 113
Function of Urea SCR System 114
Function of DEF System 114
Inducement Strategy 116
Component Parts of Urea SCR System 130
DEF Mixing Tube 130
SCR Assembly 130
DEF Tank 133
DEF Pump 135
DEF Injector 136
DEF Hose 137
DEF Tank Heating Valve 138
Boot-up System 139
Layout Drawing of Boot-up System 139
System Operating Lamp System 141
System Diagram of System Operating Lamp System 141
Function of Operation Lamp System 141
Operation of System Operating Lamp System 141
Battery Disconnect Switch 142
Function of Battery Disconnect Switch 142
Engine System 143
Layout Drawing of Engine System 143
Specifications of Engine System 144
Function of Engine System 144
Engine Control System 145
System Diagram of Engine Control 145
Operation of Engine Control System 146
Auto-Deceleration System 148
System Diagram of Auto-Deceleration System 148
Function of Auto-Deceleration System 148
Operation of Auto-Deceleration System 149
Engine Automatic Warm-up System 150
System Diagram of Engine Automatic Warm-up System 150
Function of Engine Automatic Warm-up System 151
Overheat Prevention System 152
Overheat Prevention System Diagram 152
Function of Overheat Prevention System 153
Turbocharger Protection System 155
System Diagram of Turbocharger Protection System 155
Function of Turbocharger Protection System 156
Automatic Idle Stop System 157
System Diagram of Automatic Idle Stop System 157
Function of Automatic Idle Stop System 157
Operation of Automatic Idle Stop System 157
Component Parts of Engine System 160
VGT 160
EGR System 164
EGR Valve 166
EGR Cooler 168
KCCV System 169
KCCV Ventilator 171
KDPF 173
Cooling System 178
Layout Drawing of Cooling System 178
Specifications of Cooling System 179
Control System 180
Layout Drawing of Control System 180
Machine Monitor System 183
System Diagram of Machine Monitor System 183
Function of Machine Monitor System 184
KomVision System 185
Layout Drawing of KomVision System 185
System Diagram of KomVision System 187
Function of KomVision System 187
KOMTRAX System 189
System Diagram of KOMTRAX System 189
Function of KOMTRAX System 189
Component Parts of Control System 190
Machine Monitor 190
KomVision Controller 203
KomVision Camera 207
Gateway Function Controller 208
Communication Terminal 211
Pump Controller 213
Resistor for PC-EPC Valve 217
CAN Terminating Resistor 217
Engine Controller 219
Fuel Control Dial 225
Hydraulic System 227
Layout Drawing of Hydraulic System 227
CLSS 233
Structure of CLSS 233
Operation of Unload Valve and LS Pressure 235
Pump Swash Plate Angle (Oil Flow) Control 236
Pressure Compensation Control 252
Engine and Pump Combined Control System 255
Engine and Pump Combined Control System Diagram 255
Function of Engine and Pump Combined Control System 256
Pump and Valve Control System 261
Pump and Valve Control System Diagram 261
Function of Pump and Valve Control System 262
Component Parts of Hydraulic System 264
Hydraulic Tank 264
Main Pump 266
Control Valve 290
Work Equipment System 353
Layout Drawing of Work Equipment System 353
Structure of Valve Control 358
One-Touch Power Maximizing System 360
System Diagram of One-Touch Power Maximizing System 360
Function of One-Touch Power Maximizing System 361
PPC Lock System 362
System Diagram of PPC Lock 362
Function of PPC Lock System 362
Work Equipment and Travel Automatic Lock System 363
System Diagram of Lock Lever Automatic Lock System 363
Function of Work Equipment and Travel Automatic Lock System 363
Operation of Lock Lever Automatic Lock System 364
Attachment Oil Flow Adjuster System 365
Attachment Oil Flow Adjuster System Diagram 365
Function of Attachment Oil Flow Adjuster System 366
Component Parts of Work Equipment System 367
Work Equipment and Swing PPC Valve 367
1st-Line Attachment PPC Valve (with EPC Valve) 373
2nd-Line Attachment PPC Valve 379
Solenoid Valve 381
Boom Anti-drop Valve 384
Arm Anti-Drop Valve 388
Attachment Circuit Selector Valve (For High Pressure) 392
Attachment Circuit Selector Valve (For Low Pressure) 394
Pilot Circuit Accumulator 397
Attachment Circuit Accumulator 398
Swing System 399
Layout Drawing of Swing System 399
Swing Control System Diagram 403
Function of Swing Control System 404
Component Parts of Swing System 407
Swing Motor 407
Swing Machinery 418
Swing Circle 419
Travel System 421
Layout Drawing of Travel System 421
System Diagram of Travel Control System 425
Function of Travel Control System 425
Component Parts of Travel System 427
Travel Motor 427
Final Drive 439
Travel PPC Valve 441
Center Swivel Joint 446
Undercarriage and Frame 448
Layout Drawing of Undercarriage 448
Specifications of Undercarriage 449
Work Equipment 450
Structure of Work Equipment 450
Function of Work Equipment 451
Work Equipment Clearance Adjustment Shim 452
Function of Work Equipment Clearance Adjustment Shim 452
Bucket Clearance Adjustment Shim 453
Function of Bucket Clearance Adjustment Shim 453
CAB Related Parts 454
ROPS CAB 454
Structure of ROPS CAB 454
Function of ROPS CAB 454
CAB Mount 455
Structure of CAB Mount 455
Function of CAB Mount 455
CAB Tipping Stopper 456
Structure of CAB Tipping Stopper 456
Function of CAB Tipping Stopper 456
20 Standard Value Table 457
Table of Contents 458
Standard Value Table for Engine 459
Standard Value Table for Engine: PC240LC-11 459
Standard Value Table for Machine 463
Standard Value Table for Machine: PC240LC-11 463
Machine Posture and Procedures to Measure Performance 476
Standard Value Table for Electricity 480
Standard Value Table for Electricity 480
30 Testing and Adjusting 491
Table of Contents 492
Precautions Before Work 495
Related Information on Testing and Adjusting 496
Tools for Testing and Adjusting 496
Sketch of Tools for Testing and Adjusting 503
Engine and Cooling System 505
Examine Engine Speed 505
How to Examine Engine Speed 505
Examine Boost Pressure 508
How to Examine Boost Pressure on Machine Monitor 508
How to Examine Boost Pressure by Testing Tool 509
Examine Exhaust Gas Color 510
How to Examine Exhaust Gas Color with the Handy Smoke Checker 510
How to Examine Exhaust Gas Color with Smoke Meter 511
Examine Mass Air Flow and Temperature Sensor 513
How to Examine Mass Air Flow and Temperature Sensor 513
Examine and Adjust Valve Clearance 515
How to Examine Valve Clearance 515
How to Adjust Valve Clearance 516
Examine Compression Pressure 518
How to Examine Compression Pressure 518
Examine Blowby Pressure 523
How to Examine Blowby Pressure 523
Examine Engine Oil Pressure 525
How to Examine Engine Oil Pressure 525
Examine EGR Valve and VGT Oil Pressure 526
How to Examine EGR Valve and VGT Oil Pressure 526
Examine Fuel Pressure 528
How to Examine Fuel Pressure 529
Examine Fuel Discharge, Return and Leakage 534
How to Examine Fuel Discharge, Return, and Leakage 535
Bleed Air from Fuel System 541
How to Bleed Air from Fuel System 541
Examine Fuel Circuit for Leakage 542
How to Examine Fuel System for Leakage 542
Handle Cylinder Cut-out Mode Operation 544
Handle No-Injection Cranking Operation 545
Examine and Adjust Air Conditioner Compressor Belt Tension 546
How to Examine Air Conditioner Compressor Belt 546
How to Adjust Air Conditioner Compressor Belt 546
Examine Fan Belt and Alternator Belt 548
How to Examine Fan Belt and Alternator Belt 548
Examine Automatic Tensioner 549
How to Examine Automatic Tensioner 549
Write Correction for Ash in Soot Accumulation to Engine Controller 550
How to Write Correction for Ash in Soot Accumulation to Engine Controller 550
Examine SCR Related Functions 551
Examine DEF Pump Raised Pressure 554
Examine Injection Volume from DEF Injector 557
Examine DEF Line Heater Relay 1 561
Examine DEF Line Heater Relay 2 564
Examine DEF Pump Heater Relay 566
Examine DEF Tank Heater Valve 569
Examine SCR Denitration Efficiency 572
Clean DEF Tank 576
How to Clean DEF Tank 576
Clean DEF Pump 580
How to Clean DEF Pump 580
Bleed Air from Coolant Circuit of DEF Tank 587
How to Bleed Air from Coolant Circuit of DEF Tank 587
Power Train 589
Examine Swing Circle Bearing Clearance 589
How to Examine Swing Circle Bearing Clearance 589
Undercarriage and Frame 590
Examine and Adjust Track Tension 590
How to Examine Track Tension 590
How to Adjust Track Tension 590
Hydraulic System 592
Release Remained Pressure in Hydraulic Circuit 592
How to Release Remained Pressure in Hydraulic System 592
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 593
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 594
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 600
Examine Oil Pressure of Control Circuit 603
How to Examine Oil Pressure in Control Circuit 603
Examine and adjust oil pressure in pump PC control circuit 605
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 605
Examine PC-EPC Valve Outlet Pressure 606
How to Adjust Oil Pressure in Pump PC Control Circuit 607
Examine and Adjust Oil Pressure in Pump LS Control Circuit 609
How to Examine LS Differential Pressure with Machine Monitor 609
How to Examine LS Differential Pressure by Testing Tool 610
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 613
How to Examine LS-EPC Valve Outlet Pressure 614
How to Adjust LS Valve 615
Examine Outlet Pressure of Solenoid Valve 616
How to Examine Outlet Pressure of Solenoid Valve 616
Operating Condition of Solenoid Valve 617
Examine PPC Valve Outlet Pressure 620
How to Examine Outlet Pressure in PPC Valve 620
Adjust Play of Work Equipment and Swing PPC Valves 622
How to Adjust Play of Work Equipment and Swing PPC Valves 622
Examine Pump Swash Plate Sensor 623
How to Examine pump swash plate sensor 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 626
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
Bleed Air from Hydraulic System 629
How to Bleed Air from Hydraulic System 631
CAB Related Parts 633
Examine CAB Tipping Stopper 633
How to Examine Cab Tipping Stopper 633
How to Adjust Mirrors 634
Procedure to Adjust Machine Left Front Mirror (A) 634
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 635
Procedure to Adjust Machine Right Front Mirror (B) 636
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 637
Procedure to Adjust Machine Right Side Mirror (C) 638
Electrical System 640
Set and Operate Machine Monitor 640
Operator Mode 643
Function to Show Technician Identification Status Screen 644
Function to Show Operator Identification Input Screen 644
Examine Function by LCD (Liquid Crystal Display) 645
Examine Function of Service Meter 645
Usage Limitation and Maintenance Password Change Function 645
Service Mode 648
How to Operate Service Mode 648
How to See Pre-defined Monitoring Information 650
How to Examine Self-Define Monitor Information 656
Abnormality Record Menu 667
How to See Maintenance Record 671
Maintenance Mode Setting 672
How to Set Phone Number Entry 676
Default Menu 677
Diagnostic Tests Menu 688
Adjustment Menu 697
No-Injection Cranking Operation 714
KOMTRAX Settings Menu 715
How to Show Service Message 718
How to Start Up KOMTRAX System 720
Adjust Rearview Camera Angle 725
How to Adjust Rearview Camera Angle 725
Adjust KomVision Camera Angle 728
Adjust KomVision Related Function 730
Setting of KomVision (Main Setting) 730
Setting of KomVision (Camera Setting) 732
Setting of KomVision (Camera Calibration) 734
KomVision screen – Check 12 m visibility 747
Set Region of Bluetooth(R) Compatible Radio 750
How to Set Region of Bluetooth(R) Compatible Radio 750
Handle Voltage Circuit of Engine Controller 752
Handle Battery Disconnect Switch 753
Examine Diodes 754
How to Examine Diodes by Digital Tester 754
How to Examine Diodes by Analog Tester 754
Pm Clinic 755
Pm Clinic Service 755
Pm Clinic Check Sheet 756
40 Troubleshooting 769
Table of Contents 770
Precautions Before Work 781
Related Information to Troubleshooting 782
General Troubleshooting Points 782
Troubleshooting Points for Urea SCR System 783
Sequence of Events in Troubleshooting 797
Checks Before Troubleshooting 799
Inspection Procedure Before Troubleshooting 801
Walk-Around Check 801
Test in Accordance with Testing Procedure 803
Examine Fuel Level and Type 803
Examine for Impure Ingredient in Fuel 803
Examine Fuel Prefilter 804
Examine Water Separator, Drain Water and Sediment 804
How to Replace Fuel Prefilter Cartridge 805
Examine Fuel Main Filter 806
Examine Engine Oil Level (Oil Quantity in Oil Pan) 808
Examine Coolant Level (Reservoir Tank) 809
Examine Air Cleaner Clogging 809
Clean Outer Element 810
Replace Element 812
Examine Hydraulic Oil Level 813
Examine Hydraulic Oil Strainer 814
Examine Hydraulic Oil Filter 815
Examine Oil Level in Swing Machinery Case 816
Examine Oil Level in Damper Case 817
Examine Oil Level in Final Drive Case 817
Bleed Air from Fuel System 818
Bleed Air from Hydraulic System 818
How to Examine Electric Equipment 818
Preparation for Troubleshooting of Electrical System 826
Procedure for Troubleshooting 836
Symptom and Troubleshooting Numbers 839
Information Shown in Troubleshooting Table 843
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 845
Connector List and Layout 848
Connector Contact Connection Table 865
T-Branch Box and T-Branch Adapter Table 905
Fuse Location Table 911
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 914
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 918
Failure Code Table 920
Troubleshooting by Failure Code (Display of Code) 939
Failure Code [879AKA] 939
Failure Code [879AKB] 940
Failure Code [879BKA] 941
Failure Code [879BKB] 943
Failure Code [879CKA] 945
Failure Code [879CKB] 946
Failure Code [879DKZ] 947
Failure Code [879EMC] 949
Failure Code [879FMC] 950
Failure Code [879GKX] 951
Failure Code [989L00] 953
Failure Code [989M00] 954
Failure Code [989N00] 955
Failure Code [A1U0N3] 956
Failure Code [A1U0N4] 958
Failure Code [A900FR] 960
Failure Code [A900N6] 961
Failure Code [A900NY] 962
Failure Code [AA10NX] 963
Failure Code [AB00KE] 965
Failure Code [AQ10N3] 968
Failure Code [AS00N3] 970
Failure Code [AS00R2] 972
Failure Code [AS00R3] 973
Failure Code [AS00R4] 974
Failure Code [AS00R5] 975
Failure Code [AS00R6] 976
Failure Code [AS00ZK] 977
Failure Code [AS10KM] 978
Failure Code [AS10NR] 979
Failure Code [AS10NT] 980
Failure Code [B@BAZG] 981
Failure Code [B@BAZK] 982
Failure Code [B@BCNS] 984
Failure Code [B@BCQA] 985
Failure Code [B@BCZK] 987
Failure Code [B@HANS] 989
Failure Code [CA115] 990
Failure Code [CA122] 991
Failure Code [CA123] 993
Failure Code [CA131] 995
Failure Code [CA132] 997
Failure Code [CA144] 999
Failure Code [CA145]1001
Failure Code [CA153]1003
Failure Code [CA154]1006
Failure Code [CA187]1008
Failure Code [CA221]1010
Failure Code [CA222]1012
Failure Code [CA227]1014
Failure Code [CA234]1015
Failure Code [CA238]1016
Failure Code [CA239]1018
Failure Code [CA249]1020
Failure Code [CA256]1022
Failure Code [CA271]1024
Failure Code [CA272]1026
Failure Code [CA322]1028
Failure Code [CA323]1030
Failure Code [CA324]1032
Failure Code [CA325]1034
Failure Code [CA331]1036
Failure Code [CA332]1038
Failure Code [CA343]1040
Failure Code [CA351]1041
Failure Code [CA352]1042
Failure Code [CA356]1045
Failure Code [CA357]1047
Failure Code [CA386]1049
Failure Code [CA428]1050
Failure Code [CA429]1052
Failure Code [CA435]1054
Failure Code [CA441]1056
Failure Code [CA442]1058
Failure Code [CA449]1059
Failure Code [CA451]1060
Failure Code [CA452]1062
Failure Code [CA488]1064
Failure Code [CA515]1065
Failure Code [CA516]1067
Failure Code [CA553]1069
Failure Code [CA555]1070
Failure Code [CA556]1071
Failure Code [CA559]1072
Failure Code [CA595]1075
Failure Code [CA687]1076
Failure Code [CA689]1078
Failure Code [CA691]1081
Failure Code [CA692]1083
Failure Code [CA697]1085
Failure Code [CA698]1086
Failure Code [CA731]1087
Failure Code [CA778]1089
Failure Code [CA1117]1094
Failure Code [CA1664]1095
Failure Code [CA1669]1097
Failure Code [CA1673]1098
Failure Code [CA1677]1099
Failure Code [CA1678]1100
Failure Code [CA1682]1101
Failure Code [CA1683]1103
Failure Code [CA1684]1105
Failure Code [CA1686]1107
Failure Code [CA1691]1108
Failure Code [CA1694]1111
Failure Code [CA1695]1114
Failure Code [CA1696]1115
Failure Code [CA1712]1117
Failure Code [CA1713]1120
Failure Code [CA1714]1122
Failure Code [CA1715]1123
Failure Code [CA1776]1124
Failure Code [CA1777]1127
Failure Code [CA1843]1130
Failure Code [CA1844]1132
Failure Code [CA1879]1135
Failure Code [CA1881]1137
Failure Code [CA1883]1139
Failure Code [CA1885]1142
Failure Code [CA1887]1144
Failure Code [CA1921]1146
Failure Code [CA1922]1149
Failure Code [CA1942]1154
Failure Code [CA1993]1155
Failure Code [CA2185]1158
Failure Code [CA2186]1159
Failure Code [CA2249]1161
Failure Code [CA2271]1162
Failure Code [CA2272]1165
Failure Code [CA2288]1168
Failure Code [CA2311]1169
Failure Code [CA2349]1170
Failure Code [CA2353]1173
Failure Code [CA2357]1175
Failure Code [CA2381]1176
Failure Code [CA2382]1179
Failure Code [CA2383]1182
Failure Code [CA2386]1185
Failure Code [CA2387]1187
Troubleshooting Flowchart1191
Failure Code [CA2555]1192
Failure Code [CA2556]1195
Failure Code [CA2637]1198
Failure Code [CA2639]1200
Failure Code [CA2771]1203
Failure Code [CA2777]1209
Failure Code [CA2976]1212
Failure Code [CA3133]1214
Failure Code [CA3134]1217
Failure Code [CA3135]1219
Failure Code [CA3142]1222
Failure Code [CA3143]1223
Failure Code [CA3144]1224
Failure Code [CA3146]1226
Failure Code [CA3147]1227
Failure Code [CA3148]1228
Failure Code [CA3151]1230
Failure Code [CA3165]1236
Failure Code [CA3229]1238
Failure Code [CA3231]1240
Failure Code [CA3232]1242
Failure Code [CA3235]1246
Failure Code [CA3239]1248
Failure Code [CA3241]1251
Failure Code [CA3242]1254
Failure Code [CA3251]1257
Failure Code [CA3253]1259
Failure Code [CA3254]1262
Failure Code [CA3255]1265
Failure Code [CA3256]1269
Failure Code [CA3311]1271
Failure Code [CA3312]1273
Failure Code [CA3313]1276
Failure Code [CA3314]1277
Failure Code [CA3315]1278
Failure Code [CA3316]1280
Failure Code [CA3317]1281
Failure Code [CA3318]1282
Failure Code [CA3319]1284
Failure Code [CA3321]1285
Failure Code [CA3322]1287
Failure Code [CA3419]1289
Failure Code [CA3421]1291
Failure Code [CA3497]1293
Failure Code [CA3498]1294
Failure Code [CA3543]1295
Failure Code [CA3545]1302
Failure Code [CA3547]1304
Failure Code [CA3558]1305
Failure Code [CA3559]1307
Failure Code [CA3562]1309
Failure Code [CA3563]1311
Failure Code [CA3567]1314
Failure Code [CA3568]1317
Failure Code [CA3571]1321
Failure Code [CA3572]1323
Failure Code [CA3574]1325
Failure Code [CA3575]1327
Failure Code [CA3577]1329
Failure Code [CA3578]1331
Failure Code [CA3582]1333
Failure Code [CA3583]1339
Failure Code [CA3596]1341
Failure Code [CA3649]1343
Failure Code [CA3681]1345
Failure Code [CA3682]1350
Failure Code [CA3713]1356
Failure Code [CA3717]1359
Failure Code [CA3718]1360
Failure Code [CA3725]1361
Failure Code [CA3741]1364
Failure Code [CA3748]1365
Failure Code [CA3751]1367
Failure Code [CA3755]1369
Failure Code [CA3866]1371
Failure Code [CA3867]1375
Failure Code [CA3868]1378
Failure Code [CA3899]1382
Failure Code [CA3911]1384
Failure Code [CA3912]1388
Failure Code [CA3932]1390
Failure Code [CA3933]1392
Failure Code [CA3934]1394
Failure Code [CA3935]1397
Failure Code [CA3936]1399
Failure Code [CA4151]1401
Failure Code [CA4152]1405
Failure Code [CA4155]1409
Failure Code [CA4156]1411
Failure Code [CA4157]1414
Failure Code [CA4158]1416
Failure Code [CA4159]1417
Failure Code [CA4161]1418
Failure Code [CA4162]1421
Failure Code [CA4163]1424
Failure Code [CA4164]1425
Failure Code [CA4165]1427
Failure Code [CA4166]1429
Failure Code [CA4168]1430
Failure Code [CA4169]1433
Failure Code [CA4171]1435
Failure Code [CA4249]1438
Failure Code [CA4251]1440
Failure Code [CA4259]1442
Failure Code [CA4261]1445
Failure Code [CA4277]1448
Failure Code [CA4281]1452
Failure Code [CA4459]1455
Failure Code [CA4461]1457
Failure Code [CA4658]1460
Failure Code [CA4731]1464
Failure Code [CA4732]1465
Failure Code [CA4739]1466
Failure Code [CA4768]1467
Failure Code [CA4769]1469
Failure Code [CA4842]1472
Failure Code [CA4952]1476
Failure Code [CA5115]1478
Failure Code [CA5179]1481
Failure Code [CA5181]1483
Failure Code [CA5383]1485
Failure Code [D110KB]1487
Failure Code [D19JKZ]1489
Failure Code [D811MC]1492
Failure Code [D862KA]1493
Failure Code [D8ALKA]1495
Failure Code [D8ALKB]1498
Failure Code [D8AQKR]1500
Failure Code [D8G1KT]1507
Failure Code [D8G6KT]1508
Failure Code [DA20MC]1509
Failure Code [DA22KK]1510
Failure Code [DA25KP]1513
Failure Code [DA26KP]1516
Failure Code [DA29KQ]1519
Failure Code [DA2LKA]1521
Failure Code [DA2LKB]1524
Failure Code [DA2QKR]1526
Failure Code [DA2RKR]1535
Failure Code [DAF0MB]1536
Failure Code [DAF0MC]1537
Failure Code [DAF8KB]1538
Failure Code [DAF9KQ]1540
Failure Code [DAFGMC]1541
Failure Code [DAFLKA]1542
Failure Code [DAFLKB]1545
Failure Code [DAFQKR]1547
Failure Code [DAZ9KQ]1555
Failure Code [DAZQKR]1556
Failure Code [DB2QKR]1563
Failure Code [DB2RKR]1571
Failure Code [DBP0KM]1576
Failure Code [DBP0KT]1577
Failure Code [DBP5KB]1578
Failure Code [DBP5KY]1581
Failure Code [DBPQKR]1584
Failure Code [DDNRKA]1592
Failure Code [DDNRKY]1594
Failure Code [DDNS00]1596
Failure Code [DGH2KA]1598
Failure Code [DGH2KB]1600
Failure Code [DHA4KA]1602
Failure Code [DHAAMA]1604
Failure Code [DHACMA]1606
Failure Code [DHPAMA]1608
Failure Code [DHPBMA]1611
Failure Code [DHS3MA]1614
Failure Code [DHS4MA]1617
Failure Code [DHS8MA]1620
Failure Code [DHS9MA]1623
Failure Code [DHSAMA]1626
Failure Code [DHSBMA]1629
Failure Code [DHSCMA]1632
Failure Code [DHSDMA]1635
Failure Code [DHSFMA]1638
Failure Code [DHSGMA]1641
Failure Code [DHSHMA]1644
Failure Code [DHSJMA]1647
Failure Code [DHZAMA]1650
Failure Code [DHZCL8]1654
Failure Code [DKR0MA]1655
Failure Code [DKR1MA]1658
Failure Code [DKULKA]1661
Failure Code [DKULKB]1663
Failure Code [DKULKY]1665
Failure Code [DR10KA]1667
Failure Code [DR12KA]1670
Failure Code [DR20KA]1672
Failure Code [DR21KX]1674
Failure Code [DR30KA]1676
Failure Code [DR31KX]1678
Failure Code [DR40KA]1680
Failure Code [DUMBKA]1682
Failure Code [DUMBKB]1685
Failure Code [DV20KB]1687
Failure Code [DW43KA]1689
Failure Code [DW43KB]1691
Failure Code [DW43KY]1693
Failure Code [DW45KA]1695
Failure Code [DW45KB]1698
Failure Code [DW45KY]1701
Failure Code [DW4CKY]1703
Failure Code [DW91KA]1705
Failure Code [DW91KB]1707
Failure Code [DW91KY]1709
Failure Code [DWA2KA]1711
Failure Code [DWA2KB]1713
Failure Code [DWA2KY]1715
Failure Code [DWK0KA]1717
Failure Code [DWK0KB]1719
Failure Code [DWK0KY]1721
Failure Code [DWK2KA]1723
Failure Code [DWK2KB]1725
Failure Code [DWK2KY]1727
Failure Code [DWK8KA]1729
Failure Code [DWK8KB]1731
Failure Code [DWK8KY]1733
Failure Code [DWPUKA]1735
Failure Code [DWPUKB]1737
Failure Code [DWPUKY]1739
Failure Code [DXA8KA]1741
Failure Code [DXA8KB]1743
Failure Code [DXA9KA]1745
Failure Code [DXA9KB]1747
Failure Code [DXE0KA]1749
Failure Code [DXE0KB]1751
Failure Code [DXE4KA]1753
Failure Code [DXE4KB]1755
Failure Code [DXE4KY]1757
Failure Code [DXE5KA]1759
Failure Code [DXE5KB]1761
Failure Code [DXE6KA]1763
Failure Code [DXE6KB]1765
Failure Code [DXE7KA]1767
Failure Code [DXE7KB]1769
Failure Code [DXE7KY]1771
Failure Code [DXE8KA]1773
Failure Code [DXE8KB]1775
Failure Code [DXE8KY]1777
Failure Code [DXE9KA]1779
Failure Code [DXE9KB]1781
Failure Code [DXE9KY]1783
Failure Code [DXEAKA]1785
Failure Code [DXEAKB]1787
Failure Code [DXEAKY]1789
Failure Code [DXEKKA]1791
Failure Code [DXEKKB]1793
Failure Code [DXEKKY]1795
Failure Code [DXELKA]1797
Failure Code [DXELKB]1799
Failure Code [DXELKY]1801
Failure Code [DY20KA]1803
Failure Code [DY20MA]1805
Failure Code [DY2CKB]1807
Failure Code [DY2DKB]1810
Failure Code [DY2EKB]1812
Failure Code [F311KA]1814
Failure Code [F311KB]1816
Failure Code [F312KA]1818
Failure Code [F312KB]1820
Failure Code [F313KA]1822
Failure Code [F313KB]1824
Failure Code [F314KA]1827
Failure Code [F314KB]1829
Failure Code [F315KB]1831
Failure Code [F315KY]1833
Failure Code [F316KB]1835
Failure Code [F316KY]1837
Failure Code [F318KB]1839
Failure Code [F318KY]1842
Failure Code [F31AKB]1844
Failure Code [F31AKY]1846
Failure Code [F31BKB]1848
Failure Code [F31BKY]1850
Failure Code [F31CKB]1852
Failure Code [F31CKY]1854
Failure Code [F31DKB]1856
Failure Code [F31DKY]1858
Failure Code [F31EKB]1860
Failure Code [F31EKY]1862
Troubleshooting of Electrical System (E-Mode)1864
E-1 Engine Does Not Start (Engine Does Not Crank)1864
E-2 Manual Preheating System Does Not Operate1870
E-3 Automatic Preheating System Does Not Operate1873
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1875
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1877
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1880
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1881
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1882
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1883
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1884
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1885
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1886
E-13 Water Separator Monitor Comes On in Red While Engine Runs1887
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1888
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1889
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1890
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1891
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1893
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1894
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1895
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1896
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1898
E-23 Some Areas of Machine Monitor Screen are Not Shown1899
E-24 Function Switch Does Not Operate1900
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1901
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1902
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1903
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1904
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1905
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1906
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1907
E-32 Alarm Buzzer Cannot be Canceled1909
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1910
E-34 Service Mode Cannot be Selected1911
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1912
E-36 All Work Equipment, Swing and Travel Do Not Lock1915
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1917
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1920
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1922
E-40 One-Touch Power Maximizing Function is Not Cancelled1925
E-41 Alarm Does Not Sound During Travel1926
E-42 Alarm Does Not Stop When Machine Stops1928
E-43 Horn Does Not Sound1929
E-44 Horn Does Not Stop1932
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1934
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1935
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1937
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1938
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1939
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1940
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1941
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1942
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1943
E-54 “Swing” is Not Shown Correctly with Monitoring Function1944
E-55 “Travel” is Not Shown Correctly with Monitoring Function1945
E-56 Service is Not Shown Correctly with Monitoring Function1946
E-57 Attachment Hydraulic Circuit Cannot be Changed1948
E-58 KOMTRAX System Does Not Operate Correctly1949
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1950
Information Shown in Troubleshooting Table (H-Mode)1950
System Chart of Hydraulic and Mechanical Systems1951
Failure Mode and Cause Table1953
H-1 All Work Equipment, Swing and Travel Do Not Work1962
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1963
H-3 Fine Control Performance or Response is Unsatisfactory1966
H-4 Unusual Noise is Heard from Around Hydraulic Pump1967
H-5 Engine Speed Drops Largely or Engine Stops1968
H-6 Speed or Power of Boom is Low1970
H-7 Arm Speed or Power is Low1974
H-8 Bucket Speed or Power is Low1979
H-9 Work Equipment Does Not Move in Single Operation1982
H-10 Hydraulic Drift of Boom is Large1983
H-11 Hydraulic Drift of Arm is Large1985
H-12 Hydraulic Drift of Bucket is Large1987
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1988
H-14 Time Lag of Work Equipment is Large1989
H-15 One-Touch Power Maximizing Function Does Not Operate1990
H-16 Attachment Circuit Cannot be Changed1991
H-17 Oil Flow in Attachment Circuit Cannot be Changed1992
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1993
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely1994
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1995
H-21 Machine Does Not Travel Straight1996
H-22 Machine is Not Steered Correctly or Steering Power is Low1998
H-23 Travel Speed is Low2001
H-24 One of Tracks Does Not Run2003
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2004
H-26 Upper Structure Does Not Swing to Right and Left2005
H-27 Upper Structure Swings Only to Right or Left2006
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions2007
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction2008
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2009
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2010
H-32 Shock is Large When Upper Structure Stops Swing Operation2011
H-33 There is Large Unusual Noise When It Stops Swing Operation2012
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2013
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2014
Troubleshooting of Engine (S-Mode)2015
Information Shown in Troubleshooting Table (S-Mode)2015
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position2016
S-2 Engine Cranks but No Exhaust Smoke Comes Out2017
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2018
S-4 Engine Startability is Unsatisfactory2020
S-5 Engine Does Not Pick Up Smoothly2022
S-6 Engine Stops During Operation2024
S-7 Engine Runs Rough or is Not Stable2026
S-8 Engine Lacks Power2027
S-9 KDPF Becomes Clogged in a Short Time2029
S-10 Engine Oil Consumption is Excessive2031
S-11 Oil Becomes Dirty Quickly2032
S-12 Fuel Consumption is Excessive2033
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant2034
S-14 Oil Pressure Drops2035
S-15 Fuel Mixes Into Engine Oil2037
S-16 Water Mixes Into Engine Oil (Milky)2038
S-17 Coolant Temperature Increases Too High (Overheating)2039
S-18 Unusual Noise is Heard2040
S-19 Vibration is Excessive2041
S-20 Air Cannot be Bled from Fuel Circuit2042
S-21 Active Regeneration is Done Frequently2043
S-22 Active Regeneration Continues Long2045
S-23 White Smoke is Exhausted During Active Regeneration2046
S-24 DEF Consumption is Excessive2047
S-25 There is Unusual Smell (Irritating Odor)2049
S-26 Foreign Materials Enter DEF (DEF Increases)2050
50 Disassembly and Assembly2051
Table of Contents2052
Precautions Before Work2057
Related Information on Disassembly and Assembly2058
How to Read This Manual2058
Coating Materials List2059
Special Tool List2064
Sketches of Special Tools2077
Engine and Cooling System2082
Remove and Install Supply Pump Assembly2082
How to Remove Supply Pump Assembly2082
How to Install Supply Pump Assembly2085
Remove and Install Injector Assembly2089
How to Remove Injector Assembly2089
How to Install Injector Assembly2094
Remove and Install Cylinder Head Assembly2102
How to Remove Cylinder Head Assembly2103
How to Install Cylinder Head Assembly2112
Remove and Install EGR Valve Assembly2128
How to Remove EGR Valve Assembly2128
How to Install EGR Valve Assembly2129
Remove and Install EGR Cooler Assembly2132
How to Remove EGR Cooler Assembly2132
How to Install EGR Cooler Assembly2135
Remove and Install Starter Assembly2140
How to Remove Starting Motor Assembly2140
How to Install Starting Motor Assembly2142
Remove and Install Alternator Belt2144
How to Remove Alternator Belt2144
How to Install Alternator Belt2146
Remove and Install Radiator Assembly2148
How to Remove Radiator Assembly2148
How to Install Radiator Assembly2150
Remove and Install Hydraulic Oil Cooler Assembly2152
How to Remove Hydraulic Oil Cooler Assembly2152
How to Install Hydraulic Oil Cooler Assembly2155
Remove and Install Aftercooler Assembly2158
How to Remove Aftercooler Assembly2158
How to Install Aftercooler Assembly2159
Remove and Install Engine and Main Pump Assembly2161
How to Remove Engine and Main Pump Assembly2162
How to Install Engine and Main Pump Assembly2170
Remove and Install Engine Front Oil Seal2181
How to Remove Engine Front Oil Seal2181
How to Install Engine Front Oil Seal2184
Remove and Install Engine Rear Oil Seal2188
How to Remove Engine Rear Oil Seal2188
How to Install Engine Rear Oil Seal2189
Remove and Install Fuel Cooler Assembly2192
How to Remove Fuel Cooler Assembly2192
How to Install Fuel Cooler Assembly2193
Remove and Install Engine Hood Assembly2194
How to Remove Engine Hood Assembly2194
How to Install Engine Hood Assembly2196
Remove and Install Fuel Tank Assembly2202
How to Remove Fuel Tank Assembly2202
How to Install Fuel Tank Assembly2206
Remove and Install DEF Tank Assembly2212
How to Remove DEF Tank Assembly2212
How to Install DEF Tank Assembly2217
Remove and Install DEF Tank Sensor Flange Assembly2222
How to Remove DEF Tank Sensor Flange Assembly2222
How to Install DEF Tank Sensor Flange Assembly2227
Remove and Install DEF Tank Sensor2233
How to Remove DEF Tank Sensor2233
How to Install DEF Tank Sensor2233
Remove and Install DEF Tank Strainer2240
How to Remove DEF Tank Strainer2240
How to Install DEF Tank Strainer2240
Remove and Install DEF Tank Filler Port Filter2241
How to Remove DEF Tank Filler Port Filter2241
How to Install DEF Tank Filler Port Filter2243
Remove and Install KDPF Assembly2246
How to Remove KDPF Assembly2246
How to Install KDPF Assembly2248
Disassemble and Assemble KDPF Assembly2250
How to Disassemble KDPF Assembly2251
How to Assemble KDPF Assembly2254
Remove and Install SCR Assembly2259
How to Remove SCR Assembly2259
How to Install SCR Assembly2261
Remove and Install KDPF and SCR Assembly2263
How to Remove KDPF and SCR Assembly2263
How to Install KDPF and SCR Assembly2269
Remove and Install KDPF and SCR Assembly Bracket2275
How to Remove KDPF and SCR Assembly Bracket2275
How to Install KDPF and SCR Assembly Bracket2281
Remove and Install Bellows Pipe Assembly2288
How to Remove Bellows Pipe Assembly2288
How to Install Bellows Pipe Assembly2290
Remove and Install KCCV Assembly2294
How to Remove KCCV Assembly2294
How to Install KCCV Assembly2297
Remove and Install DEF Mixing Tube2301
How to Remove DEF Mixing Tube2301
How to Install DEF Mixing Tube2306
Remove and Install DEF Injector2311
How to Remove DEF Injector2311
How to Install DEF Injector2313
Remove and Install DEF Pump2315
How to Remove DEF Pump2315
How to Install DEF Pump2317
Remove and Install DEF Hose2320
How to Remove DEF Hose2320
How to Install DEF Hose2328
Remove and Install Air Cleaner Assembly2334
How to Remove Air Cleaner Assembly2334
How to Install Air Cleaner Assembly2335
Remove and Install Air Conditioner Compressor Assembly2337
How to Remove Air Conditioner Compressor Assembly2337
How to Install Air Conditioner Compressor Assembly2339
Remove and Install Air Conditioner Condenser Assembly2342
How to Remove Air Conditioner Condenser Assembly2342
How to Install Air Conditioner Condenser Assembly2343
Power Train2344
Remove and Install Travel Motor and Final Drive Assembly2344
How to Remove Travel Motor and Final Drive Assembly2344
How to Install Travel Motor and Final Drive Assembly2345
Disassemble and Assemble Final Drive Assembly2347
How to Disassemble Final Drive Assembly2347
How to Assemble Final Drive Assembly2351
Remove and Install Swing Motor and Swing Machinery Assembly2360
How to Remove Swing Motor and Swing Machinery Assembly2360
How to Install Swing Motor and Swing Machinery Assembly2363
Disassemble and Assemble Swing Machinery Assembly2366
How to Disassemble Swing Machinery Assembly2366
How to Assemble Swing Machinery Assembly2370
Remove and Install Swing Circle Assembly2377
How to Remove Swing Circle Assembly2377
How to Install Swing Circle Assembly2377
Undercarriage and Frame2379
Separate and Connect Track Assembly2379
How to Separate Track Assembly2379
How to Install Track Assembly2381
Remove and Install Sprocket2384
How to Remove Sprocket2384
How to Install Sprocket2384
Remove and Install Idler and Idler Cushion Assembly2386
How to Remove Idler and Idler Cushion Assembly2386
How to Install Idler and Idler Cushion Assembly2387
Disassemble and Assemble Idler Assembly2388
How to Disassemble Idler Assembly2388
How to Assemble Idler Assembly2389
Disassemble and Assemble Idler Cushion Assembly2393
How to Disassemble Idler Cushion Assembly2394
How to Assemble Idler Cushion Assembly2395
Disassemble and Assemble Track Roller Assembly2396
How to Disassemble Track Roller Assembly2397
How to Assemble Track Roller Assembly2398
Disassemble and Assemble Carrier Roller Assembly2400
How to Disassemble Carrier Roller Assembly2400
How to Assemble Carrier Roller Assembly2402
Remove and Install Revolving Frame Assembly2404
How to Remove Revolving Frame Assembly2404
How to Install Revolving Frame Assembly2406
Remove and Install Counterweight Assembly2409
How to Remove Counterweight Assembly2409
How to Install Counterweight Assembly2412
Hydraulic System2416
Remove and Install Center Swivel Joint Assembly2416
How to Remove Center Swivel Joint Assembly2416
How to Install Center Swivel Joint Assembly2418
Disassemble and Assemble Center Swivel Joint Assembly2421
How to Disassemble Center Swivel Joint Assembly2422
How to Assemble Center Swivel Joint Assembly2423
Remove and Install Hydraulic Tank Assembly2424
How to Remove Hydraulic Tank Assembly2424
How to Install Hydraulic Tank Assembly2427
Remove and Install Main Pump Assembly2431
How to Remove Main Pump Assembly2431
How to Install Main Pump Assembly2434
Remove and Install Control Valve Assembly2438
How to Remove Control Valve Assembly2438
How to Install Control Valve Assembly2445
Disassemble and Assemble Control Valve Assembly2453
How to Replace Pressure Compensation Valve Seal Ring2453
How to Assemble Control Valve Assembly2455
Disassemble and Assemble Work Equipment PPC Valve Assembly2459
How to Disassemble Work Equipment PPC Valve Assembly2459
How to Assemble Work Equipment PPC Valve Assembly2459
Disassemble and Assemble Travel PPC Valve Assembly2461
How to Disassemble Travel PPC Valve Assembly2461
How to Assemble Travel PPC Valve Assembly2462
Work Equipment2464
Remove and Install Work Equipment Assembly2464
How to Remove Work Equipment Assembly2464
How to Install Work Equipment Assembly2468
Remove and Install Boom Anti-drop Valve Assembly2474
How to Remove Boom Anti-drop Valve Assembly2474
How to Install Boom Anti-drop Valve Assembly2476
Remove and Install Arm Anti-Drop Valve Assembly2477
How to Remove Arm Anti-Drop Valve Assembly2477
How to Install Arm Anti-Drop Valve Assembly2479
Disassemble and Assemble Anti-Drop Valve Assembly2480
How to Disassemble Anti-Drop Valve Assembly2480
How to Assemble Anti-Drop Valve Assembly2480
Disassemble and Assemble Work Equipment Cylinder Assembly2481
How to Disassemble Work Equipment Cylinder Assembly2481
How to Assemble Work Equipment Cylinder Assembly2484
CAB Related Parts2490
Remove and Install Operator Cab Assembly2490
How to Remove Operator Cab Assembly2490
How to Install Operator Cab Assembly2496
Remove and Install Operator Cab Glass (Adhered Glass)2503
How to Remove Operator Cab Glass (Adhered Glass)2505
How to Install Operator Cab Glass (Adhered Glass)2505
Remove and Install Front Window Assembly2515
How to Remove Front Window Assembly2515
How to Install Front Window Assembly2518
Remove and Install Floor Frame Assembly2524
How to Remove Floor Frame Assembly2524
How to Install Floor Frame Assembly2531
Remove and Install Air Conditioner Unit Assembly2538
How to Remove Air Conditioner Unit Assembly2538
How to Install Air Conditioner Unit Assembly2544
Remove and Install Operator Seat2551
How to Remove Operator Seat2551
How to Install Operator Seat2553
How to Remove and Install Seat Belt2556
How to Remove Seat Belt2556
How to Install Seatbelt2557
Remove and Install Work Equipment Control Lever Assembly2558
How to Remove Work Equipment Control Lever Assembly2558
How to Install Work Equipment Control Lever Assembly2564
Remove and Install Front Wiper Assembly2573
How to Remove Front Wiper Assembly2573
How to Install Front Wiper Assembly2578
Electrical System2587
Remove and Install Engine Controller Assembly2587
How to Remove Engine Controller Assembly2587
How to Install Engine Controller Assembly2589
Remove and Install Pump Controller Assembly2590
How to Remove Pump Controller Assembly2590
How to Install Pump Controller Assembly2594
Remove and Install KomVision Controller Assembly2599
How to Remove KomVision Controller Assembly2599
How to Install KomVision Controller Assembly2600
Remove and Install Machine Monitor Assembly2601
How to Remove Machine Monitor Assembly2601
How to Install Machine Monitor Assembly2604
Remove and Install Pump Swash Plate Sensor2607
How to Remove Pump Swash Plate Sensor2607
How to Install Pump Swash Plate Sensor2608
Remove and Install Mass Air Flow and Temperature Sensor2609
How to Remove Mass Air Flow and Temperature Sensor2609
How to Install Mass Air Flow and Temperature Sensor2610
Remove and Install KCCV Crankcase Pressure Sensor2611
How to Remove KCCV Crankcase Pressure Sensor2611
How to Install KCCV Crankcase Pressure Sensor2612
Remove and Install SCR Temperature Sensor2614
How to Remove SCR Temperature Sensor2614
How to Install SCR Temperature Sensor2616
Remove and Install KomVision Camera2619
How to Remove KomVision Camera2619
How to Install KomVision Camera2620
Remove and Install Gateway Function Controller Assembly2622
How to Remove Gateway Function Controller Assembly2622
How to Install Gateway Function Controller Assembly2627
Remove and Install Communication Terminal Wiring Harness2632
How to Remove Communication Terminal Wiring Harness2632
How to Install Communication Terminal Wiring Harness2640
Remove and Install Communication Terminal2649
How to Remove Communication Terminal2649
How to Install Communication Terminal2651
60 Maintenance Standard2655
Table of Contents2656
Engine and Cooling System2657
Maintenance Standard for Engine Mount2657
Maintenance Standard for Cooling System2658
Power Train2659
Maintenance Standard for Swing Circle2659
Maintenance Standard for Swing Machinery2660
Maintenance Standard for Final Drive2662
Maintenance Standard for Sprocket2664
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2665
Undercarriage and Frame2666
Maintenance Standard for Track Frame and Idler Cushion2666
Maintenance Standard for Idler2668
Maintenance Standard for Track Roller2670
Maintenance Standard for Carrier Roller2671
Maintenance Standard for Track Shoes2672
Maintenance Standard for Triple Shoes2675
Maintenance Standard for Swamp Shoes2676
Maintenance Standard for Road Liner2677
Hydraulic System2678
Maintenance Standard for Hydraulic Tank2678
Maintenance Standard for Main Pump2679
Maintenance Standard for LS-EPC Valve2680
Maintenance Standard for PC-EPC Valve2681
Maintenance Standard for Swing Motor2682
Maintenance Standard for Travel Motor2685
Maintenance Standard for Control Valve2688
Maintenance Standard for Boom Anti-Drop Valve2698
Maintenance Standard for Arm Anti-Drop Valve2700
Maintenance Standard for Work Equipment and Swing PPC Valve2702
Maintenance Standard for Travel PPC Valve2705
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2708
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2709
Maintenance Standard for 2nd-Line Attachment PPC Valve2711
Maintenance Standard for Solenoid Valve2713
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)2714
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)2715
Maintenance Standard for Center Swivel Joint2716
Work Equipment2717
Maintenance Standard for Work Equipment Linkage2717
Dimensions of Arm2722
Dimensions of Bucket2724
Maintenance Standard for Boom Cylinder2726
Maintenance Standard for Boom Cylinder (Large Diameter Piston)2727
Maintenance Standard for Arm Cylinder2728
Maintenance Standard for Bucket Cylinder2729
80 Appendix2731
Table of Contents2732
Precautions Before Work2734
Air Conditioner System2735
Precautions for Refrigerant2735
Air Conditioner Component2736
Specifications of Air Conditioner2738
Structure and Function of Refrigeration Cycle2739
Outline of Refrigeration Cycle2740
Component Parts of Air Conditioner System2742
Air Conditioner Unit2742
Configuration Diagram of Air Conditioner Unit2742
Function of Air Conditioner Unit2744
Component Parts of Air Conditioner Unit2746
Function of Evaporator as Air Conditioner Unit Component2747
Function of Heater Core as Air Conditioner Unit Component2747
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2747
Function of Servo Motor as Air Conditioner Unit Component2747
Structure of Expansion Valve as Air Conditioner Unit Component2748
Function of Expansion Valve as Air Conditioner Unit Component2748
Operate Expansion Valve as Air Conditioner Unit Component2748
Function of Dual Pressure Switch2749
Air Conditioner Controller2750
Structure of Air Conditioner Controller2750
Compressor2751
Structure of Compressor2751
Specifications of Compressor2751
Function of Compressor2751
Condenser2752
Structure of Condenser2752
Specifications of Condenser2752
Function of Condenser2752
Air Conditioner Related Sensors2754
Structure of Sunlight Sensor2754
Function of Sunlight Sensor2754
Structure of Outside Temperature Sensor2754
Function of Outside Air Temperature Sensor2754
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2756
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2758
System Diagram of Air Conditioner2760
Input and Output Signals of Air Conditioner Controller2761
Function of Air Conditioner Controller2762
Locations of Air Conditioner Parts and Layout of Connectors2763
Examine Air Leakage (Duct)2767
How to Examine Air Leakage (Duct)2767
Examine Air Conditioner with Self-Diagnosis Function2769
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2770
Examine Vent (Mode) Changeover2771
How to Examine Vent (Mode) Changeover2771
Examine Fresh/Recirc Air Changeover2773
How to Examine Fresh/Recirc Air Changeover2773
Examine Sunlight Sensor2774
How to Examine Sunlight Sensor2774
Examine Refrigerant (Dual) Pressure Switch2775
How to Examine Refrigerant (Dual) Pressure Switch2775
Examine Relay2776
How to Examine Relay2776
Air Conditioner Troubleshooting Chart 12777
Air Conditioner Troubleshooting Chart 22778
Information Shown in Troubleshooting Table2781
Failure Code [879AKA]2782
Failure Code [879AKB]2783
Failure Code [879BKA]2784
Failure Code [879BKB]2786
Failure Code [879CKA]2788
Failure Code [879CKB]2789
Failure Code [879DKZ]2790
Failure Code [879EMC]2792
Failure Code [879FMC]2793
Failure Code [879GKX]2794
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2796
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2798
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2801
A-4 Troubleshooting for Fresh/Recirc Air Changeover2803
Troubleshooting by Gauge Pressure2805
Connect Service Tool2808
How to Connect Service Tool2808
Precautions for Disconnection and Connection of Air Conditioner Piping2810
Handle Compressor Oil2812
How to Replace Desiccant2814
90 Circuit Diagrams2817
Table of Contents2818
Hydraulic Circuit Diagram2819
Symbols Used in Hydraulic Circuit Diagram2819
Hydraulic Circuit Diagram2823
Electrical Circuit Diagram2825
Symbols Used in Electric Circuit Diagram2825
Electrical Circuit Diagram (1/10)2829
Electrical Circuit Diagram (2/10)2831
Electrical Circuit Diagram (3/10)2833
Electrical Circuit Diagram (4/10)2835
Electrical Circuit Diagram (5/10)2837
Electrical Circuit Diagram (6/10)2839
Electrical Circuit Diagram (7/10)2841
Electrical Circuit Diagram (8/10)2843
Electrical Circuit Diagram (9/10)2845
Electrical Circuit Diagram (10/10)2847
Index2849

S.M 28/12/24