Komatsu Hydraulic Excavator PC490LCi-11 Shop Manual SEN06592-19 PDF

Description

Komatsu Hydraulic Excavator PC490LCi-11 Shop Manual SEN06592-19 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC490LCi-11 Shop Manual SEN06592-19 – PDF DOWNLOAD

Language : English
Pages :3888
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu Hydraulic Excavator PC490LCi-11 Shop Manual SEN06592-19 – PDF DOWNLOAD

SERIAL NUMBERS 85113 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC490LCi-11 Shop Manual SEN06592-19 – PDF DOWNLOAD

SERIAL NUMBERS 85113 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 24
Foreword, Safety, Basic Information 27
How to Read the Shop Manual 27
Safety Notice for Operation 29
Precautions to Prevent Fire 37
Procedures If Fire Occurs 39
Precautions When You Discard Waste Materials 40
Procedures for Exhaust Gas Regulations 41
Precautions for DEF 42
General Character and Precautions for Handling 42
Precautions When You Add 42
Precautions for Storage 42
Precautions for Fire Hazard and Leakage 42
Other Precautions 42
Store DEF 43
Precautions When You Handle Hydraulic Equipment 44
Precautions When You Disconnect and Connect Pipings 47
Precautions When You Handle Electrical Equipment 54
Precautions When You Handle Fuel System Equipment 56
Precautions When You Handle Intake System Equipment 57
Practical Use of KOMTRAX 58
Disconnect and Connect Push-Pull Type Coupler 59
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 61
Precautions for Disconnection and Connection of Connectors 63
Disconnect and Connect Deutsch Connector 67
How to Disconnect and Connect Slide Lock Type Connector 68
Disconnect and Connect Connector with Lock to Pull 70
Disconnect and Connect Connector with Lock to Push 71
Disconnect and Connect Connector with Housing to Rotate 73
How to Read the Codes for Electric Cable 74
Explanation of Terms for Maintenance Standard 78
Standard Tightening Torque Table 81
Conversion Table 88
01 Specification 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: PC490LCI-11 95
Working Range Drawings 97
Working Range: PC490LCI-11 97
Specifications 98
Specifications: PC490LCI-11 98
Weight Table 102
Weight Table: PC490LCI-11 102
Table of Fuel, Coolant, and Lubricants 104
10 Structure and Function 105
Table of Contents 106
Urea SCR System 110
Layout Drawing of Urea SCR System 110
Urea SCR System Diagram 114
Function of Urea SCR System 115
Function of DEF System 115
Inducement Strategy 117
Component Parts of Urea SCR System 131
DEF Mixing Tube 131
SCR Assembly 131
DEF Tank 134
DEF Pump 136
DEF Injector 137
DEF Hose 138
DEF Tank Heating Valve 139
Boot-up System 140
Layout Drawing of Boot-up System 140
System Operating Lamp System 142
System Diagram of System Operating Lamp System 142
Function of Operation Lamp System 142
Battery Disconnect Switch 144
Function of Battery Disconnect Switch 144
Engine System 145
Layout Drawing of Engine System 145
Specifications of Engine System 146
Function of Engine System 147
Engine Control System 148
System Diagram of Engine Control 148
Function of Engine Control System 149
Auto-Deceleration System 151
System Diagram of Auto-Deceleration System 151
Function of Auto-Deceleration System 151
Operation of Auto-Deceleration System 152
Engine Automatic Warm-up System 153
System Diagram of Engine Automatic Warm-up System 153
Function of Engine Automatic Warm-up System 154
Overheat Prevention System 155
Overheat Prevention System Diagram 155
Function of Overheat Prevention System 156
Turbocharger Protection System 158
System Diagram of Turbocharger Protection System 158
Function of Turbocharger Protection System 159
Automatic Idle Stop System 160
System Diagram of Automatic Idle Stop System 160
Function of Automatic Idle Stop System 160
Component Parts of Engine System 163
VGT 163
EGR System 166
EGR Valve 168
EGR Cooler 170
KCCV System 171
KCCV Ventilator 172
KDPF 174
Cooling System 179
Layout Drawing of Cooling System 179
Specifications of Cooling System 180
Fan Speed Control System of Hydraulic Fan 182
Fan Speed Control System Diagram of Hydraulic Fan 182
Function of Fan Speed Control System of Hydraulic Fan 183
Engine Output Control System of Hydraulic Fan 184
Engine Output Control System Diagram of Hydraulic Fan 184
Function of Engine Output Control System of Hydraulic Fan 185
Fan Reverse Rotation System of Hydraulic Fan 187
Fan Reverse Rotation System Diagram of Hydraulic Fan 187
Function of Fan Reverse Rotation System of Hydraulic Fan 187
Component Parts of Cooling System 188
Cooling Fan Pump 188
Cooling Fan Motor 195
Control System 202
Layout Drawing of Control System 202
Layout Drawing of Control System (Multi GNSS Support, 104 inch Display) 205
Machine Monitor System 208
System Diagram of Machine Monitor System 208
KOMTRAX System 209
System Diagram of KOMTRAX System 209
Function of KOMTRAX System 209
Component Parts of Control System 210
Machine Monitor 210
Pump Controller 224
Resistor for PC-EPC Valve 228
CAN Terminating Resistor 228
Engine Controller 230
Fuel Control Dial 236
Fuel Feed Pump 238
Fuel Feed Pump Switch 239
Hydraulic System 240
Layout Drawing of Hydraulic System 240
CLSS 242
Structure of CLSS 242
Operation of Unload Valve and LS Pressure 244
Pump Swash Plate Angle (Oil Flow) Control 245
Pressure Compensation Control 261
Engine and Pump Combined Control System 265
Engine and Pump Combined Control System Diagram 265
Function of Engine and Pump Combined Control System 267
Pump and Valve Control System 272
Pump and Valve Control System Diagram 272
Function of Pump and Valve Control System 273
Component Parts of Hydraulic System 275
Hydraulic Tank 275
Main Pump 277
Control Valve 303
Work Equipment System 367
Layout Drawing of Work Equipment System 367
Structure of Valve Control 372
One-Touch Power Maximizing System 373
System Diagram of One-Touch Power Maximizing System 373
Function of One-Touch Power Maximizing System 374
Machine Push-up System 375
Machine Push-up System Diagram 375
Function of Machine Push-up System 376
PPC Lock System 377
System Diagram of PPC Lock 377
Function of PPC Lock System 377
Work Equipment and Travel Automatic Lock System 378
System Diagram of Lock Lever Automatic Lock System 378
Function of Work Equipment and Travel Automatic Lock System 378
Operation of Lock Lever Automatic Lock System 379
Attachment Oil Flow Adjuster System 380
Attachment Oil Flow Adjuster System Diagram 380
Function of Attachment Oil Flow Adjuster System 381
Component Parts of Work Equipment System 382
Work Equipment and Swing PPC Valve 382
1st-Line Attachment PPC Valve (with EPC Valve) 388
Solenoid Valve 393
Attachment Circuit Selector Valve 395
1st-Line Attachment Variable Relief Valve 397
Attachment Bypass Solenoid Valve 400
Pilot Circuit Accumulator 402
Attachment Circuit Accumulator 403
ICT System 404
Layout Drawing of ICT System 404
Layout Drawing of ICT System (Multi GNSS Support, 104 inch Display) 405
System Diagram of ICT Control System 407
Bucket Edge Position Detection System 408
Bucket Edge Position Detection System Diagram 408
Function of Bucket Edge Position Detection System 408
Operation of Bucket Edge Position Detection System 408
The Intelligent Machine Control System 410
Function of Intelligent Machine Control System 410
Auto Grade Assist Control 410
Auto Stop Control 417
Cushion System for Arm IN End 425
Cushion System for Arm IN End Diagram 425
Function of Cushion System for Arm IN End 425
Operation of Cushion System for Arm IN End 425
Boom Secondary Drive Switch 427
Control Function When Boom Secondary Drive Switch is Turned to ON Position 427
Component Parts of ICT System 428
ICT Sensor Controller 428
Work Equipment Controller 432
Control Box 436
GNSS Receiver 441
GNSS Antenna 446
IMU Sensor 447
Intelligent Machine Control EPC Valve 449
Stroke Sensor for Boom Cylinder 452
Stroke Sensor for Arm Cylinder 453
Stroke and Reset Sensor for Bucket Cylinder 454
Reset Sensor for Boom Cylinder 457
Reset Sensor for Arm Cylinder 458
Boom Spool Stroke Sensor 459
Arm Spool Stroke Sensor 460
Swing System 462
Layout Drawing of Swing System 462
Swing Control System Diagram 467
Function of Swing Control System 468
Component Parts of Swing System 471
Swing Motor 471
Swing Machinery 482
Swing Circle 484
Travel System 486
Layout Drawing of Travel System 486
System Diagram of Travel Control System 490
Function of Travel Control System 491
Component Parts of Travel System 492
Travel Motor 492
Final Drive 505
Travel PPC Valve 506
Center Swivel Joint 511
Undercarriage and Frame 513
Layout Drawing of Undercarriage 513
Specifications of Undercarriage 513
Work Equipment 514
Structure of Work Equipment 514
Function of Work Equipment 515
Work Equipment Clearance Adjustment Shim 516
Function of Work Equipment Clearance Adjustment Shim 516
Bucket Clearance Adjustment Shim 517
Function of Bucket Clearance Adjustment Shim 517
CAB Related Parts 518
ROPS CAB 518
Structure of ROPS CAB 518
Function of ROPS CAB 518
CAB Mount 519
Structure of CAB Mount 519
Function of CAB Mount 519
CAB Tipping Stopper 520
Structure of CAB Tipping Stopper 520
Function of CAB Tipping Stopper 520
20 Standard Value Table 521
Table of Contents 522
Standard Value Table for Engine 523
Standard Value Table for Engine: PC490LCI-11 523
Standard Value Table for Machine 526
Standard Value Table for Machine: PC490LCI-11 526
Machine Posture and Procedures to Measure Performance 551
30 Testing and Adjusting 555
Table of Contents 556
Precautions Before Work 560
Related Information on Testing and Adjusting 561
Tools for Testing and Adjusting 561
Sketch of Tools for Testing and Adjusting 572
Engine and Cooling System 574
Examine Engine Speed 574
How to Examine Engine Speed 574
Examine Boost Pressure 577
How to Examine Boost Pressure on Machine Monitor 577
How to Examine Boost Pressure by Testing Tool 578
Examine Exhaust Gas Color 579
How to Examine Exhaust Gas Color with the Handy Smoke Checker 579
How to Examine Exhaust Gas Color with Smoke Meter 580
Examine Mass Air Flow and Temperature Sensor 581
How to Examine Mass Air Flow and Temperature Sensor 581
Examine and Adjust Valve Clearance 583
Check Valve Clearance 583
Adjust Valve Clearance 586
Examine Compression Pressure 587
How to Examine Compression Pressure 587
Examine Blowby Pressure 590
How to Examine Blowby Pressure 590
Examine Engine Oil Pressure 592
Examine Engine Oil Pressure on Machine Monitor 592
Examine Engine Oil Pressure by Testing Tool 592
Examine EGR Valve and VGT Oil Pressure 594
How to Examine EGR Valve and VGT Oil Pressure 594
Examine Fuel Pressure 596
How to Examine Fuel Pressure 596
Examine Fuel Return Rate and Leakage 598
How to Examine Fuel Return Rate and Leakage 598
Bleed Air from Fuel System 601
How to Bleed Air from Fuel System 601
Examine Fuel Circuit for Leakage 603
How to Examine Fuel System for Leakage 603
Handle Cylinder Cut-out Mode Operation 605
Handle No-Injection Cranking Operation 606
Examine and Adjust Air Conditioner Compressor Belt Tension 607
How to Examine Air Conditioner Compressor Belt Tension 607
How to Adjust Air Conditioner Compressor Belt Tension 607
Clean Fuel Doser 609
How to Clean Fuel Doser 609
Write Injector Compensation Value to Engine Controller 611
Write Injector Compensation Value 611
Write Correction for Ash in Soot Accumulation to Engine Controller 617
How to Write Correction for Ash in Soot Accumulation to Engine Controller 617
Examine SCR Related Functions 618
Examine DEF Pump Raised Pressure 621
Examine Injection Volume from DEF Injector 624
Examine DEF Line Heater Relay 1 628
Examine DEF Line Heater Relay 2 630
Examine DEF Pump Heater Relay 633
Examine DEF Tank Heater Valve 636
Examine SCR Denitration Efficiency 639
Clean DEF Tank 643
How to Clean DEF Tank 643
Clean DEF Pump 647
How to Clean DEF Pump 647
Power Train 654
Examine Swing Circle Bearing Clearance 654
How to Examine Swing Circle Bearing Clearance 654
Undercarriage and Frame 655
Examine and Adjust Track Tension 655
How to Examine Track Tension 655
How to Adjust Track Tension 655
Hydraulic System 657
Release Remained Pressure in Hydraulic Circuit 657
How to Release Remained Pressure in Hydraulic System 657
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 659
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 660
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 667
Examine Oil Pressure of Control Circuit 671
Examine Oil Pressure in Control Circuit 671
Examine and adjust oil pressure in pump PC control circuit 673
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 673
Examine PC-EPC Valve Outlet Pressure 674
How to Adjust Oil Pressure in Pump PC Control Circuit 675
Examine and Adjust Oil Pressure in Pump LS Control Circuit 677
Examine LS Differential Pressure with Machine Monitor 677
Examine LS Differential Pressure by Testing Tool 678
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 679
How to Examine LS-EPC Valve Outlet Pressure 680
Adjust LS Valve 681
Examine Outlet Pressure of Solenoid Valve 682
How to Examine Outlet Pressure of Solenoid Valve 682
Operating Condition of Solenoid Valve 683
Examine PPC Valve Outlet Pressure 685
Examine Outlet Pressure in PPC Valve 685
Adjust Play of Work Equipment and Swing PPC Valves 687
How to Adjust Play of Work Equipment and Swing PPC Valves 687
Examine Pump Swash Plate Sensor 688
How to Examine pump swash plate sensor 688
Examine Cooling Fan Speed 689
How to Examine Cooling Fan Speed 689
Examine Oil Pressure in Fan Pump Circuit 690
How to Examine Oil Pressure in Fan Pump Circuit 690
Examine Fan Pump EPC Electric Current 692
How to Examine Fan Pump EPC Electric Current 692
Examine Fan Pump EPC Solenoid Valve Outlet Pressure 693
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 693
Examine Parts Which Cause Hydraulic Drift of Work Equipment 695
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 695
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 695
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 696
Examine Oil Leakage 697
Examine Oil Leakage from Boom Cylinder 697
Examine Oil Leakage of Arm Cylinder 697
Examine Oil Leakage of Bucket Cylinder 698
How to Examine Oil Leakage of Swing Motor 698
How to Examine Oil Leakage of Travel Motor 699
Bleed Air from Hydraulic System 700
How to Bleed Air from Hydraulic System 702
CAB Related Parts 705
Examine CAB Tipping Stopper 705
How to Examine Cab Tipping Stopper 705
How to Adjust Mirrors 706
Procedure to Adjust Machine Left Front Mirror (A) 706
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 707
Procedure to Adjust Machine Right Front Mirror (B) 708
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 709
Procedure to Adjust Machine Right Side Mirror (C) 710
Electrical System 712
Set and Operate Machine Monitor 712
Operator Mode 716
Function to Show Technician Identification Status Screen 716
Function to Show Operator Identification Input Screen 716
Examine Function by LCD (Liquid Crystal Display) 717
Examine Function of Service Meter 717
Usage Limitation and Maintenance Password Change Function 717
Service Mode 720
Operate Service Mode 720
How to See Pre-defined Monitoring Information 721
How to Examine Self-Define Monitor Information 728
Abnormality Record Menu 742
How to See Maintenance Record 746
Maintenance Mode Setting 747
Set Phone Number Entry 751
Default Menu 753
Diagnostic Tests Menu 762
Adjustment Menu 772
No-Injection Cranking Operation 790
KOMTRAX Settings Menu 792
Show Service Message 794
How to Start Up KOMTRAX Terminal 796
Adjust Rearview Camera Angle 801
How to Adjust Rearview Camera Angle 801
Adjust KomVision Camera Angle 804
How to Adjust KomVision Camera Angle 805
Adjust KomVision Related Function 809
Setting of KomVision (Main Setting) 809
Setting of KomVision (Camera Setting) 811
Setting of KomVision (Camera Calibration) 813
KomVision screen – Check 12 m visibility 826
Set Region of Bluetooth(R) Compatible Radio 829
Set Region of Bluetooth(R) Compatible Radio 829
Handle Voltage Circuit of Engine Controller 831
Handle Battery Disconnect Switch 832
Examine Diodes 833
Examine Diodes by Digital Tester 833
How to Examine Diodes by Analog Tester 833
ICT System 834
Set and Operate Control Box 834
How to Set the Starting Switch Interlock Function of the Control Box 837
How to Select Excavator Model in the Control Box 843
Set GNSS Receiver Type 848
Set Heading Mode 853
Switch Grade Transitions Fineness on Control Box 858
Monitoring and Logging Function on Control Box 862
Set Tilt Automatic Control Function 867
Calibrate Intelligent Machine Control 871
PPC Pressure Sensor Calibration 873
Control Map Calibration 954
How to Examine the Intelligent Machine Control System1103
Calibrate IMU Sensor for Yaw Angle1107
Calibrate IMU Sensor1114
Procedure to be Done If an Error Occurs During Calibration of IMU Sensor1128
Work Equipment Cylinder Calibration1128
If Error Occurs During Calibration of Work Equipment Cylinder1141
General Calibration of Bucket Blade Edge Position, Boom Dimensions, Arm Dimensions, Bucket Link Dimensions, and GNSS Antenna Position with Total Station1143
Calibration of Boom Dimensions and Arm Dimensions with Total Station1196
Calibration of Bucket Link Dimensions with Total Station1217
Calibration of GNSS Antenna with Total Station1255
Input Range of the Measured Values in Calibration with Total Station1280
Examine the Input Values in Calibration with Total Station1282
Procedure to be Done If an Error Occurs During Calibration with Total Station1282
Calibration of GNSS Antenna Without Total Station1283
Calibration of Bucket Blade Edge Position Without Total Station1287
Input Range of the Measured Values in Calibration Without Total Station1297
Procedure to be Done If an Error Occurs During Calibration Without Total Station1298
Pm Clinic1300
Pm Clinic Service1300
Pm Clinic Check Sheet: PC490LCI-111302
40 Troubleshooting1315
Table of Contents1316
Precautions Before Work1329
Related Information to Troubleshooting1330
General Troubleshooting Points1330
Troubleshooting Points for Urea SCR System1331
Sequence of Events in Troubleshooting1345
Checks Before Troubleshooting1347
Inspection Procedure Before Troubleshooting1349
Walk-Around Check1349
Test in Accordance with Testing Procedure1351
Examine Fuel Level and Type1351
Examine for Impure Ingredient in Fuel1352
Examine Fuel Prefilter1352
Examine Water Separator, Drain Water and Sediment1352
Replace Fuel Prefilter Cartridge1353
Examine Fuel Main Filter1354
Examine Engine Oil Level (Oil Quantity in Oil Pan)1355
Examine Coolant Level (Reservoir Tank)1357
Examine Air Cleaner Clogging1357
Clean Outer Element1358
Replace Element1360
Examine Hydraulic Oil Level1361
Examine Hydraulic Oil Strainer1361
Examine Hydraulic Oil Filter1362
Examine Oil Level in Swing Machinery Case1363
Examine Oil Level in Damper Case1364
Examine Oil Level in Final Drive Case1364
Bleed Air from Fuel System1365
Bleed Air from Hydraulic System1365
How to Examine Electric Equipment1365
Preparation for Troubleshooting of Electrical System1373
Preparation for Troubleshooting of Machine Monitor1373
Preparation for Troubleshooting of Engine Controller1373
Preparation for Troubleshooting of Pump Controller1374
Preparation for Troubleshooting of ICT Sensor Controller1374
Preparation for Troubleshooting of Work Equipment Controller1376
Preparation for Troubleshooting of KOMTRAX Terminal1377
Preparation for Troubleshooting of Control Box (121inch Display)1377
Preparation for Troubleshooting of Control Box (104 inch Display)1377
Preparation for Troubleshooting of GNSS Receiver1377
Preparation for Troubleshooting of GNSS Receiver (Multi GNSS Support)1378
How to Disconnect and Connect Connector with a Special Lock1378
Procedure for Troubleshooting1382
Symptom and Troubleshooting Numbers1385
Information Shown in Troubleshooting Table1390
Connector List and Layout1392
Connector List and Layout (Multi GNSS Support, 104 inch Display)1412
Connector Contact Connection Table1433
T-Branch Box and T-Branch Adapter Table1473
Fuse Location Table1479
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1482
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])1486
Failure Code Table1488
Troubleshooting by Failure Code (Display of Code)1510
Failure Code [879AKA]1510
Failure Code [879AKB]1511
Failure Code [879BKA]1512
Failure Code [879BKB]1514
Failure Code [879CKA]1516
Failure Code [879CKB]1517
Failure Code [879DKZ]1518
Failure Code [879EMC]1520
Failure Code [879FMC]1521
Failure Code [879GKX]1522
Failure Code [989L00]1524
Failure Code [989M00]1525
Failure Code [989N00]1526
Failure Code [A1U0N3]1527
Failure Code [A1U0N4]1529
Failure Code [A900FR]1531
Failure Code [A900N6]1532
Failure Code [A900NY]1533
Failure Code [AA10NX]1534
Failure Code [AB00KE]1536
Failure Code [AQ10N3]1539
Failure Code [AS00N3]1541
Failure Code [AS00R2]1543
Failure Code [AS00R3]1544
Failure Code [AS00R4]1545
Failure Code [AS00R5]1546
Failure Code [AS00R6]1547
Failure Code [AS00ZK]1548
Failure Code [AS10KM]1549
Failure Code [AS10NR]1550
Failure Code [AS10NT]1551
Failure Code [B@BAZG]1552
Failure Code [B@BAZK]1553
Failure Code [B@BCNS]1555
Failure Code [B@BCQA]1556
Failure Code [B@BCZK]1558
Failure Code [B@HANS]1560
Failure Code [CA115]1561
Failure Code [CA122]1562
Failure Code [CA123]1564
Failure Code [CA131]1566
Failure Code [CA132]1568
Failure Code [CA135]1570
Failure Code [CA141]1572
Failure Code [CA144]1574
Failure Code [CA145]1576
Failure Code [CA153]1578
Failure Code [CA154]1581
Failure Code [CA187]1584
Failure Code [CA221]1586
Failure Code [CA222]1588
Failure Code [CA227]1590
Failure Code [CA234]1591
Failure Code [CA238]1592
Failure Code [CA239]1594
Failure Code [CA249]1596
Failure Code [CA256]1598
Failure Code [CA271]1600
Failure Code [CA272]1602
Failure Code [CA273]1603
Failure Code [CA274]1605
Failure Code [CA322]1606
Failure Code [CA323]1608
Failure Code [CA324]1610
Failure Code [CA325]1612
Failure Code [CA331]1614
Failure Code [CA332]1616
Failure Code [CA343]1618
Failure Code [CA351]1619
Failure Code [CA352]1620
Failure Code [CA356]1623
Failure Code [CA357]1625
Failure Code [CA386]1627
Failure Code [CA441]1628
Failure Code [CA442]1630
Failure Code [CA449]1631
Failure Code [CA451]1632
Failure Code [CA452]1634
Failure Code [CA515]1636
Failure Code [CA516]1638
Failure Code [CA553]1640
Failure Code [CA555]1641
Failure Code [CA556]1642
Failure Code [CA559]1643
Failure Code [CA595]1648
Failure Code [CA687]1649
Failure Code [CA689]1651
Failure Code [CA691]1653
Failure Code [CA692]1655
Failure Code [CA697]1657
Failure Code [CA698]1658
Failure Code [CA731]1659
Failure Code [CA778]1660
Failure Code [CA1117]1663
Failure Code [CA1664]1664
Failure Code [CA1669]1667
Failure Code [CA1673]1668
Failure Code [CA1677]1669
Failure Code [CA1678]1670
Failure Code [CA1682]1671
Failure Code [CA1683]1673
Failure Code [CA1684]1674
Failure Code [CA1686]1676
Failure Code [CA1691]1677
Failure Code [CA1694]1680
Failure Code [CA1695]1682
Failure Code [CA1696]1683
Failure Code [CA1712]1685
Failure Code [CA1713]1688
Failure Code [CA1714]1690
Failure Code [CA1715]1691
Failure Code [CA1776]1692
Failure Code [CA1777]1695
Failure Code [CA1843]1698
Failure Code [CA1844]1700
Failure Code [CA1879]1703
Failure Code [CA1881]1705
Failure Code [CA1883]1707
Failure Code [CA1885]1710
Failure Code [CA1887]1712
Failure Code [CA1921]1714
Failure Code [CA1922]1717
Failure Code [CA1923]1722
Failure Code [CA1924]1724
Failure Code [CA1925]1726
Failure Code [CA1927]1728
Failure Code [CA1928]1730
Failure Code [CA1942]1732
Failure Code [CA1963]1733
Failure Code [CA1977]1736
Failure Code [CA1993]1739
Failure Code [CA2185]1742
Failure Code [CA2186]1744
Failure Code [CA2249]1746
Failure Code [CA2265]1747
Failure Code [CA2266]1749
Failure Code [CA2271]1751
Failure Code [CA2272]1753
Failure Code [CA2349]1755
Failure Code [CA2353]1757
Failure Code [CA2357]1759
Failure Code [CA2381]1760
Failure Code [CA2382]1762
Failure Code [CA2383]1764
Failure Code [CA2386]1766
Failure Code [CA2387]1768
Failure Code [CA2555]1769
Failure Code [CA2556]1772
Failure Code [CA2637]1774
Failure Code [CA2639]1776
Failure Code [CA2732]1779
Failure Code [CA2733]1781
Failure Code [CA2741]1783
Failure Code [CA2765]1784
Failure Code [CA2771]1785
Failure Code [CA2777]1791
Failure Code [CA2878]1794
Failure Code [CA2881]1797
Failure Code [CA2976]1800
Failure Code [CA3133]1802
Failure Code [CA3134]1804
Failure Code [CA3135]1806
Failure Code [CA3142]1809
Failure Code [CA3143]1810
Failure Code [CA3144]1811
Failure Code [CA3146]1813
Failure Code [CA3147]1814
Failure Code [CA3148]1815
Failure Code [CA3151]1817
Failure Code [CA3165]1823
Failure Code [CA3167]1825
Failure Code [CA3229]1828
Failure Code [CA3231]1830
Failure Code [CA3232]1832
Failure Code [CA3235]1836
Failure Code [CA3239]1838
Failure Code [CA3241]1841
Failure Code [CA3242]1844
Failure Code [CA3251]1847
Failure Code [CA3253]1849
Failure Code [CA3254]1852
Failure Code [CA3255]1855
Failure Code [CA3256]1859
Failure Code [CA3311]1861
Failure Code [CA3312]1863
Failure Code [CA3313]1866
Failure Code [CA3314]1867
Failure Code [CA3315]1868
Failure Code [CA3316]1871
Failure Code [CA3317]1872
Failure Code [CA3318]1873
Failure Code [CA3319]1875
Failure Code [CA3321]1876
Failure Code [CA3322]1878
Failure Code [CA3419]1881
Failure Code [CA3421]1883
Failure Code [CA3497]1885
Failure Code [CA3498]1886
Failure Code [CA3543]1887
Failure Code [CA3545]1894
Failure Code [CA3547]1896
Failure Code [CA3558]1897
Failure Code [CA3559]1899
Failure Code [CA3562]1901
Failure Code [CA3563]1903
Failure Code [CA3567]1906
Failure Code [CA3568]1909
Failure Code [CA3571]1913
Failure Code [CA3572]1915
Failure Code [CA3574]1917
Failure Code [CA3575]1919
Failure Code [CA3577]1921
Failure Code [CA3578]1923
Failure Code [CA3582]1925
Failure Code [CA3583]1931
Failure Code [CA3596]1933
Failure Code [CA3649]1935
Failure Code [CA3681]1937
Failure Code [CA3682]1942
Failure Code [CA3713]1948
Failure Code [CA3717]1951
Failure Code [CA3718]1952
Failure Code [CA3725]1953
Failure Code [CA3748]1956
Failure Code [CA3751]1958
Failure Code [CA3755]1960
Failure Code [CA3866]1962
Failure Code [CA3867]1966
Failure Code [CA3868]1969
Failure Code [CA3899]1973
Failure Code [CA3911]1975
Failure Code [CA3912]1979
Failure Code [CA3932]1981
Failure Code [CA3933]1983
Failure Code [CA3934]1985
Failure Code [CA3935]1988
Failure Code [CA3936]1990
Failure Code [CA4151]1992
Failure Code [CA4152]1996
Failure Code [CA4155]2000
Failure Code [CA4156]2002
Failure Code [CA4157]2005
Failure Code [CA4158]2007
Failure Code [CA4159]2008
Failure Code [CA4161]2009
Failure Code [CA4162]2012
Failure Code [CA4163]2015
Failure Code [CA4164]2017
Failure Code [CA4165]2019
Failure Code [CA4166]2021
Failure Code [CA4168]2023
Failure Code [CA4169]2026
Failure Code [CA4171]2028
Failure Code [CA4249]2031
Failure Code [CA4251]2033
Failure Code [CA4259]2035
Failure Code [CA4261]2037
Failure Code [CA4277]2040
Failure Code [CA4281]2044
Failure Code [CA4459]2047
Failure Code [CA4461]2049
Failure Code [CA4658]2052
Failure Code [CA4731]2056
Failure Code [CA4732]2057
Failure Code [CA4739]2058
Failure Code [CA4768]2059
Failure Code [CA4769]2061
Failure Code [CA4842]2064
Failure Code [CA4952]2068
Failure Code [CA5115]2070
Failure Code [CA5179]2073
Failure Code [CA5181]2075
Failure Code [CA5383]2077
Failure Code [D110KB]2079
Failure Code [D19JKZ]2081
Failure Code [D811MC]2084
Failure Code [D862KA]2085
Failure Code [D8ALKA]2086
Failure Code [D8ALKB]2088
Failure Code [D8AQKR]2090
Failure Code [DA20MC]2098
Failure Code [DA22KK]2099
Failure Code [DA25KP]2101
Failure Code [DA29KQ]2104
Failure Code [DA2LKA]2106
Failure Code [DA2LKB]2108
Failure Code [DA2QKR]2110
Failure Code [DA2RKR]2119
Failure Code [DAF0MB]2128
Failure Code [DAF0MC]2129
Failure Code [DAF8KB]2130
Failure Code [DAF9KQ]2132
Failure Code [DAFGMC]2133
Failure Code [DAFLKA]2134
Failure Code [DAFLKB]2136
Failure Code [DAFQKR]2138
Failure Code [DAZ9KQ]2146
Failure Code [DAZQKR]2147
Failure Code [DB2QKR]2155
Failure Code [DB2RKR]2163
Failure Code [DB90MC]2171
Failure Code [DB92KK]2172
Failure Code [DB95KP]2174
Failure Code [DB96KP]2178
Failure Code [DB99KQ]2182
Failure Code [DB9LKA]2187
Failure Code [DB9LKB]2189
Failure Code [DB9QKR]2191
Failure Code [DB9RKR]2200
Failure Code [DBR0MC]2209
Failure Code [DBR2KK]2210
Failure Code [DBR5KP]2213
Failure Code [DBR6KP]2215
Failure Code [DBR9KQ]2217
Failure Code [DBRLKA]2222
Failure Code [DBRLKB]2224
Failure Code [DBRQKR]2226
Failure Code [DBRRKR]2235
Failure Code [DBRSKB]2244
Failure Code [DBRTKB]2246
Failure Code [DBUSKR] (121inch Display)2248
Failure Code [DBUSKR] (104 inch Display)2252
Failure Code [DD20MA]2256
Failure Code [DDNRKA]2259
Failure Code [DDNRKY]2261
Failure Code [DDNS00]2263
Failure Code [DGH2KA]2265
Failure Code [DGH2KB]2267
Failure Code [DHA4KA]2269
Failure Code [DHAAMA]2271
Failure Code [DHACMA]2273
Failure Code [DHPAMA]2275
Failure Code [DHPBMA]2278
Failure Code [DHS3MA]2281
Failure Code [DHS4MA]2284
Failure Code [DHS8MA]2287
Failure Code [DHS9MA]2290
Failure Code [DHSAMA]2293
Failure Code [DHSBMA]2296
Failure Code [DHSCMA]2299
Failure Code [DHSDMA]2302
Failure Code [DHSFMA]2305
Failure Code [DHSGMA]2308
Failure Code [DHSHMA]2311
Failure Code [DHSJMA]2314
Failure Code [DHZAMA]2317
Failure Code [DHZCL8]2321
Failure Code [DK80KM]2322
Failure Code [DK80KR]2323
Failure Code [DK80KT]2329
Failure Code [DKG1KM]2330
Failure Code [DKG1L8]2331
Failure Code [DKR0MA]2332
Failure Code [DKR1MA]2335
Failure Code [DKT0KM]2338
Failure Code [DKT0L8]2339
Failure Code [DKT1KA]2340
Failure Code [DKT1KB]2342
Failure Code [DKT2KA]2344
Failure Code [DKT2KB]2346
Failure Code [DKT4KM]2348
Failure Code [DKT4L8]2349
Failure Code [DKT5KA]2350
Failure Code [DKT5KB]2352
Failure Code [DKT6KA]2354
Failure Code [DKT6KB]2356
Failure Code [DKT8KA]2358
Failure Code [DKT8KB]2360
Failure Code [DKT9KA]2362
Failure Code [DKT9KB]2364
Failure Code [DKTAKA]2366
Failure Code [DKTAKB]2368
Failure Code [DKTAMB]2370
Failure Code [DKTBKX]2371
Failure Code [DKTBMC]2373
Failure Code [DKTEMB]2374
Failure Code [DKTFKX]2376
Failure Code [DKTFMC]2378
Failure Code [DKTJMB]2379
Failure Code [DKU1MA]2381
Failure Code [DKU2MA]2382
Failure Code [DKUGKA]2383
Failure Code [DKUGKB]2385
Failure Code [DKUGKY]2387
Failure Code [DKUHKA]2389
Failure Code [DKUHKB]2391
Failure Code [DKUHKY]2393
Failure Code [DKULKA]2395
Failure Code [DKULKB]2397
Failure Code [DKULKY]2399
Failure Code [DKV0KA]2401
Failure Code [DKV0KY]2404
Failure Code [DKV1KA]2406
Failure Code [DKV1KY]2408
Failure Code [DKV2KA]2410
Failure Code [DKV2KY]2412
Failure Code [DKV3KA]2414
Failure Code [DKV3KY]2416
Failure Code [DKV4MA]2418
Failure Code [DKV5MA]2421
Failure Code [DKV6MA]2424
Failure Code [DKV7MA]2427
Failure Code [DKV8MA]2430
Failure Code [DKV9MA]2433
Failure Code [DKVAMA]2436
Failure Code [DKVBKA]2439
Failure Code [DKVBKB]2441
Failure Code [DKVBKY]2443
Failure Code [DKVCKA]2445
Failure Code [DKVCKB]2447
Failure Code [DKVCKY]2449
Failure Code [DKVDKA]2451
Failure Code [DKVDKB]2453
Failure Code [DKVDKY]2455
Failure Code [DKVDMA]2457
Failure Code [DLM3KA]2458
Failure Code [DLM3KB]2460
Failure Code [DLM3MB]2462
Failure Code [DR21KX]2463
Failure Code [DR31KX]2465
Failure Code [DV20KB]2467
Failure Code [DW43KA]2469
Failure Code [DW43KB]2471
Failure Code [DW43KY]2473
Failure Code [DW45KA]2475
Failure Code [DW45KB]2478
Failure Code [DW45KY]2481
Failure Code [DW4CKY]2483
Failure Code [DW4FKA]2484
Failure Code [DW4FKB]2487
Failure Code [DW4FKY]2489
Failure Code [DW4GKA]2492
Failure Code [DW4GKB]2495
Failure Code [DW4GKY]2497
Failure Code [DW4SKA]2499
Failure Code [DW4SKB]2501
Failure Code [DW4SKY]2503
Failure Code [DW7BKA]2505
Failure Code [DW7BKB]2507
Failure Code [DW7BKY]2508
Failure Code [DW91KA]2509
Failure Code [DW91KB]2511
Failure Code [DW91KY]2513
Failure Code [DWA2KA]2515
Failure Code [DWA2KB]2517
Failure Code [DWA2KY]2519
Failure Code [DWK0KA]2521
Failure Code [DWK0KB]2523
Failure Code [DWK0KY]2525
Failure Code [DWK2KA]2527
Failure Code [DWK2KB]2529
Failure Code [DWK2KY]2531
Failure Code [DWK8KA]2533
Failure Code [DWK8KB]2535
Failure Code [DWK8KY]2537
Failure Code [DWPUKA]2539
Failure Code [DWPUKB]2541
Failure Code [DWPUKY]2543
Failure Code [DX16KA]2545
Failure Code [DX16KB]2547
Failure Code [DXA8KA]2549
Failure Code [DXA8KB]2551
Failure Code [DXA9KA]2552
Failure Code [DXA9KB]2554
Failure Code [DXE0KA]2556
Failure Code [DXE0KB]2558
Failure Code [DXE4KA]2560
Failure Code [DXE4KB]2562
Failure Code [DXE4KY]2564
Failure Code [DXE5KA]2566
Failure Code [DXE5KB]2568
Failure Code [DXE6KA]2570
Failure Code [DXE6KB]2572
Failure Code [DXE7KA]2574
Failure Code [DXE7KB]2576
Failure Code [DXE7KY]2578
Failure Code [DXE8KA]2580
Failure Code [DXE8KB]2582
Failure Code [DXE8KY]2584
Failure Code [DXE9KA]2586
Failure Code [DXE9KB]2588
Failure Code [DXE9KY]2590
Failure Code [DXEAKA]2592
Failure Code [DXEAKB]2594
Failure Code [DXEAKY]2596
Failure Code [DXEKKA]2598
Failure Code [DXEKKB]2600
Failure Code [DXEKKY]2602
Failure Code [DXELKA]2604
Failure Code [DXELKB]2606
Failure Code [DXELKY]2608
Failure Code [DY20KA]2610
Failure Code [DY20MA]2612
Failure Code [DY2CKB]2614
Failure Code [DY2DKB]2617
Failure Code [DY2EKB]2619
Failure Code [FE0AKA]2621
Troubleshooting of Electrical System (E-Mode)2623
Engine Does Not Start (Engine Does Not Crank)2623
Manual Preheating System Does Not Operate2629
Automatic Preheating System Does Not Operate2632
While Preheating is in Operation, Preheating Monitor Does Not Come On2634
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing2636
While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow2639
While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow2640
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation2641
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation2642
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation2643
Charge Level Monitor Comes On in Red While Engine is in Operation2644
Fuel Level Monitor Comes On in Red While Engine is in Operation2645
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation2646
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation2647
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation2648
Fuel Gauge Does Not Move from Minimum or Maximum2649
Display of Fuel Gauge is Different from Actual Fuel Level2651
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum2652
Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature2653
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum2654
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature2656
Some Areas of Machine Monitor Screen are Not Shown2657
Function Switch Does Not Operate2658
Automatic Warm-up System Does Not Operate (in Cold Weather)2659
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated2660
Auto-Decelerator is Not Operated or Canceled with Lever2661
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated2662
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed2663
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated2664
Travel Speed Does Not Change Even When You Change Travel Speed2665
Alarm Buzzer Does Not Stop2667
Service Meter is Not Shown While Starting Switch is in OFF Position2668
Service Mode Cannot be Selected2669
All Work Equipment, Swing, Travel Do Not Operate2670
All Work Equipment, Swing, Travel Cannot be Locked2672
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position2673
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated2676
One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor is Not Shown2678
One-Touch Power Maximizing Function is Not Cancelled2680
Travel Alarm Does Not Operate During Travel2681
Travel Alarm Does Not Stop When Machine Stops2683
Horn Does Not Sound2684
Horn Does Not Stop2688
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated2690
Windshield Wiper Does Not Operate When Wiper Switch is Operated2691
When Window Washer Switch is Operated, Window Washer Does Not Operate2693
“Boom Raise” is Not Shown Correctly with Monitoring Function2694
“Boom Lower” is Not Shown Correctly with Monitoring Function2695
“Arm OUT” is Not Shown Correctly with Monitoring Function2696
“Arm IN” is Not Shown Correctly with Monitoring Function2697
Bucket DUMP is Not Shown Correctly with Monitoring Function2698
Bucket CURL is Not Shown Correctly with Monitoring Function2699
Swing is Not Shown Correctly with Monitoring Function2700
Travel is Not Shown Correctly with Monitoring Function2701
Service is Not Shown Correctly with Monitoring Function2702
Attachment Hydraulic Circuit Cannot be Changed2704
KOMTRAX System Does Not Operate Correctly2705
Machine Push-up Function Cannot be Canceled2706
Machine Push-up Function Does Not Operate2708
Control Box Shows Message [GPS Receiver Not Connected!] and [Slope Sensor Not Connected!], and Then Shuts Down (121inch Display)2709
Control Box Shows Message [GPS Receiver Not Connected!] and [Slope Sensor Not Connected!], and Then Shuts Down (104 inch Display)2714
Control Box Shows Message [GPS receiver not connected!] (121inch Display)2717
Control Box Shows Message [GPS receiver not connected!] (104 inch Display)2721
Control Box Shows Message [Waiting for radio link]2725
Control Box Shows Message [Tilt Bucket Sensor Offline!]2726
Control Box Shows Message [Waiting for satellites]2727
Control Box Shows Message [GPS receiver not connected!] Show Production2728
Control Box Shows Message [Sensors are invalid]2732
Control Box Shows Message [Waiting to initialize]2735
Control Box Shows Message [Initializing]2736
Control Box Shows Message [No GPS Localization]2737
Control Box Shows Message [Low precisions]2738
Control Box Displays [Out of design area]2739
Control Box Shows Message [Avoidance Area Breach!]2740
Control Box Can Not be Turned on2741
Control Box Does Not Display Intelligent Machine Control Screen2742
Control Box Does Not Display Hydraulic Excavator Image2743
Control Box Does Not Display Design Surface2744
Control Box Touch Panel Does Not Respond2745
Control Box Touch Panel is Inaccurate2746
When You Examine and Adjust the Bucket Edge Position, the Value is Different from Actual Machine2747
Semi-Auto Mode is Not Shown When Auto/Manual Switch is Pushed2749
Auto Grade Assist Control Does Not Operate While “Semi-auto limited digging mode” is Shown2750
Auto Stop Control Does Not Operate While “Semi-Auto Mode” is Shown2751
Blade Edge Position on Design Surface is Not Accurate When Auto Grade Assist Function is on2752
Blade Edge Stop Position is Not Accurate for Design Surface When Auto Stop Control Function is on2754
Facing Angle Compass Does Not Become Perpendicular to Target2756
NG Occurs Frequently in IMU Calibration Diagnosis2757
Cushion for Arm IN End Does Not Work or is Weak2758
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2761
Information Shown in Troubleshooting Table (H-Mode)2761
Failure Mode and Cause Table2762
All Work Equipment, Swing and Travel Do Not Work2770
All Work Equipment, Swing, and Travel Lack Speed or Power2771
Fine Control Performance or Response is Unsatisfactory2773
Unusual Noise is Heard from Around Hydraulic Pump2774
Engine Speed Drops Largely or Engine Stops2775
Boom Speed or Power is Low2777
Arm Speed or Power is Low2782
Bucket Speed or Power is Low2787
Work Equipment Does Not Move in Single Operation2790
Hydraulic Drift of Boom is Large2792
Hydraulic Drift of Arm is Large2794
Hydraulic Drift of Bucket is Large2796
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves2797
Time Lag of Work Equipment is Large2798
All Work Equipment Do Not Operate2799
One-Touch Power Maximizing Function Does Not Operate2800
Machine Push-up Function Does Not Operate2801
Attachment Circuit Cannot be Changed2802
Oil Flow in Attachment Circuit Cannot be Changed2803
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower2804
In Mixed Operation of Swing and Travel, Travel Speed Falls Largely2805
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low2806
Machine Does Not Travel Straight2807
Machine is Not Steered Well or Steering Power is Low2809
Travel Speed is Low2812
One of Tracks Does Not Run2814
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2815
Upper Structure Does Not Swing in Two Directions of Right and Left2816
Machine Swings Only in One Direction2817
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left2818
Swing Acceleration or Swing Speed is Low in Only One Direction2819
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2820
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2821
Shock is Large When Upper Structure Stops Swing Operation2822
Large Unusual Noise is Heard When Upper Structure Stops2823
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2824
Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2825
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2826
Unusual Noise is Heard from Around Fan2827
Troubleshooting of Engine (S-Mode)2828
Information Shown in Troubleshooting Table (S-Mode)2828
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position2829
S-2 Engine Cranks but No Exhaust Smoke Comes Out2830
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2831
S-4 Engine Startability is Unsatisfactory2832
S-5 Engine Does Not Pick Up Smoothly2834
S-6 Engine Stops During Operation2836
S-7 Engine Runs Rough or is Not Stable2838
S-8 Engine Lacks Power2839
S-9 KDPF Becomes Clogged in a Short Time2841
S-10 Engine Oil Consumption is Excessive2843
S-11 Oil Becomes Dirty Quickly2844
S-12 Fuel Consumption is Excessive2845
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant2846
S-14 Oil Pressure Drops2847
S-15 Fuel Mixes Into Engine Oil2849
S-16 Water Mixes Into Engine Oil (Milky)2850
S-17 Coolant Temperature Increases Too High (Overheating)2851
S-18 Unusual Noise is Heard2852
S-19 Vibration is Excessive2853
S-20 Air Cannot be Bled from Fuel Circuit2854
S-21 Active Regeneration is Done Frequently2855
S-22 Active Regeneration Continues Long2857
S-23 White Smoke is Exhausted During Active Regeneration2858
S-24 DEF Consumption is Excessive2859
S-25 There is Unusual Smell (Irritating Odor)2861
S-26 Foreign Materials Enter DEF (DEF Increases)2862
50 Disassembly and Assembly2863
Table of Contents2864
Precautions Before Work2870
Related Information on Disassembly and Assembly2871
How to Read This Manual2871
Coating Materials List2872
Special Tool List2877
Sketches of Special Tools2891
Engine and Cooling System2898
Remove and Install Supply Pump Assembly2898
Remove Supply Pump Assembly2898
Install Supply Pump Assembly2904
Remove and Install Injector Assembly2913
How to Remove Injector Assembly2913
How to Install Injector Assembly2919
Remove and Install Fuel Doser Assembly2929
How to Remove Fuel Doser2929
How to Install Fuel Doser2930
Remove and Install Cylinder Head Assembly2932
How to Remove Cylinder Head Assembly2933
How to Install Cylinder Head Assembly2942
Remove and Install EGR Valve Assembly2955
Remove EGR Valve Assembly2955
Install EGR Valve Assembly2957
Remove and Install EGR Cooler Assembly2959
How to Remove EGR Cooler Assembly2959
How to Install EGR Cooler Assembly2963
Remove and Install Starter Assembly2969
Remove Starting Motor Assembly2969
Install Starting Motor Assembly2970
Remove and Install Alternator Belt2972
Remove Alternator Belt2972
Install Alternator Belt2975
Remove and Install Radiator Assembly2980
How to Remove Radiator Assembly2980
How to Install Radiator Assembly2982
Remove and Install Cooling Fan and Fan Motor Assembly2985
Remove Cooling Fan and Fan Motor Assembly2985
Install Cooling Fan and Fan Motor Assembly2989
Remove and Install Hydraulic Oil Cooler Assembly2994
How to Remove Hydraulic Oil Cooler Assembly2994
How to Install Hydraulic Oil Cooler Assembly2996
Remove and Install Aftercooler Assembly2998
Remove Aftercooler Assembly2998
Install Aftercooler Assembly3000
Remove and Install Engine and Main Pump Assembly3004
Remove Engine and Main Pump Assembly3005
Install Engine and Main Pump Assembly3023
Remove and Install Engine Front Oil Seal3042
How to Remove Engine Front Oil Seal3043
How to Install Engine Front Oil Seal3045
Remove and Install Engine Rear Oil Seal3049
How to Remove Engine Rear Oil Seal3050
How to Install Engine Rear Oil Seal3053
Remove and Install Engine Hood Assembly3059
How to Remove Engine Hood Assembly3059
How to Install Engine Hood Assembly3067
Remove and Install Fuel Tank Assembly3078
Remove Fuel Tank Assembly3078
Install Fuel Tank Assembly3083
Remove and Install DEF Tank Assembly3087
How to Remove DEF Tank Assembly3087
How to Install DEF Tank Assembly3093
Remove and Install DEF Tank Sensor Flange Assembly3098
How to Remove DEF Tank Sensor Flange Assembly3098
How to Install DEF Tank Sensor Flange Assembly3105
Remove and Install DEF Tank Sensor3111
Remove DEF Tank Sensor3111
Install DEF Tank Sensor3111
Remove and Install DEF Tank Filler Port Filter3118
Remove DEF Tank Filler Port Filter3118
Install DEF Tank Filler Port Filter3120
Remove and Install KDPF Assembly3123
How to Remove KDPF Assembly3123
How to Install KDPF Assembly3127
Disassemble and Assemble KDPF Assembly3132
Disassemble KDPF Assembly3133
Assemble KDPF Assembly3138
Remove and Install SCR Assembly3145
How to Remove SCR Assembly3145
How to Install SCR Assembly3148
Remove and Install KDPF and SCR Assembly3152
How to Remove KDPF and SCR Assembly3152
Install KDPF and SCR Assembly3157
Remove and Install KDPF and SCR Assembly Bracket3162
Remove KDPF and SCR Assembly Bracket3162
Install KDPF and SCR Assembly Bracket3167
Remove and Install Bellows Pipe Assembly3176
How to Remove Bellows Pipe Assembly3176
How to Install Bellows Pipe Assembly3178
Remove and Install KCCV Assembly3182
Remove KCCV Assembly3182
Install KCCV Assembly3183
Remove and Install DEF Mixing Tube3187
Remove DEF Mixing Tube3187
Install DEF Mixing Tube3191
Remove and Install DEF Injector3197
Remove DEF Injector3197
Install DEF Injector3201
Remove and Install DEF Pump3206
Remove DEF Pump3206
Install DEF Pump3208
Remove and Install DEF Hose3209
Remove DEF Hose3209
Install DEF Hose3215
Remove and Install Air Cleaner Assembly3223
Remove Air Cleaner Assembly3223
Install Air Cleaner Assembly3224
Remove and Install Air Conditioner Compressor Assembly3227
Remove Air Conditioner Compressor Assembly3227
How to Install Air Conditioner Compressor Assembly3230
Remove and Install Air Conditioner Condenser Assembly3234
How to Remove Air Conditioner Condenser Assembly3234
How to Install Air Conditioner Condenser Assembly3235
Power Train3237
Remove and Install Travel Motor and Final Drive Assembly3237
Remove Travel Motor and Final Drive Assembly3237
Install Travel Motor and Final Drive Assembly3238
Disassemble and Assemble Final Drive Assembly3239
Disassemble Final Drive Assembly3239
Assemble Final Drive Assembly3244
Remove and Install Swing Motor and Swing Machinery Assembly3250
Remove Swing Motor and Swing Machinery Assembly3250
Install Swing Motor and Swing Machinery Assembly3251
Disassemble and Assemble Swing Machinery Assembly3253
Disassemble Swing Machinery Assembly3253
Assemble Swing Machinery Assembly3257
Remove and Install Swing Circle Assembly3263
Remove Swing Circle Assembly3263
Install Swing Circle Assembly3263
Undercarriage and Frame3265
Separate and Connect Track Assembly3265
Separate Track Assembly3265
Install Track Assembly3267
Remove and Install Sprocket3270
Remove Sprocket3270
Install Sprocket3270
Remove and Install Idler and Idler Cushion Assembly3272
Remove Idler and Idler Cushion Assembly3272
Install Idler and Idler Cushion Assembly3273
Disassemble and Assemble Idler Assembly3275
Disassemble Idler Assembly3275
Assemble Idler Assembly3277
Disassemble and Assemble Idler Cushion Assembly3282
Disassemble Idler Cushion Assembly3283
Assemble Idler Cushion Assembly3285
Disassemble and Assemble Track Roller Assembly3288
Disassemble Track Roller Assembly3289
Assemble Track Roller Assembly3290
Disassemble and Assemble Carrier Roller Assembly3294
Disassemble Carrier Roller Assembly3294
Assemble Carrier Roller Assembly3296
Remove and Install Revolving Frame Assembly3299
Remove Revolving Frame Assembly3299
Install Revolving Frame Assembly3302
Remove and Install Counterweight Assembly3306
Remove Counterweight Assembly3306
Install Counterweight Assembly3307
Hydraulic System3309
Remove and Install Center Swivel Joint Assembly3309
Remove Center Swivel Joint Assembly3309
Install Center Swivel Joint Assembly3311
Disassemble and Assemble Center Swivel Joint Assembly3313
Disassemble Center Swivel Joint Assembly3314
Assemble Center Swivel Joint Assembly3314
Remove and Install Hydraulic Tank Assembly3316
Remove Hydraulic Tank Assembly3316
How to Install Hydraulic Tank Assembly3321
Remove and Install Main Pump Assembly3327
Remove Main Pump Assembly3327
Install Main Pump Assembly3331
Remove and Install Junction Block Assembly for Intelligent Machine Control3337
Remove Junction Block Assembly for Intelligent Machine Control3337
Install Junction Block Assembly for Intelligent Machine Control3342
Remove and Install Pressure Sensor for Intelligent Machine Control3348
How to Remove Pressure Sensor for Intelligent Machine Control3348
How to Install Pressure Sensor for Intelligent Machine Control3350
Remove and Install Boom Spool Stroke Sensor3354
How to Remove Boom Spool Stroke Sensor3354
How to Install Boom Spool Stroke Sensor3354
Remove and Install Arm Spool Stroke Sensor3356
How to Remove Arm Spool Stroke Sensor3356
How to Install Arm Spool Stroke Sensor3356
Remove and Install Junction Block Bypass Adapter for Intelligent Machine Control3358
How to Remove Junction Block Bypass Adapter for Intelligent Machine Control3359
How to Remove Junction Block Bypass Adapter for Intelligent Machine Control3360
Remove and Install Control Valve Assembly3362
How to Remove Control Valve Assembly3362
How to Install Control Valve Assembly3367
Disassemble and Assemble Control Valve Assembly3372
Replace Pressure Compensation Valve Seal Ring3373
Assemble Control Valve Assembly3374
Disassemble and Assemble Work Equipment PPC Valve Assembly3379
Disassemble Work Equipment PPC Valve Assembly3379
How to Assemble Work Equipment PPC Valve Assembly3380
Disassemble and Assemble Travel PPC Valve Assembly3382
Disassemble Travel PPC Valve Assembly3382
How to Assemble Travel PPC Valve Assembly3383
Work Equipment3385
Remove and Install Bucket Assembly3385
How to Remove Bucket Assembly3385
How to Install Bucket Assembly3385
Remove and Install Arm Assembly3387
Remove Arm Assembly3387
How to Install Arm Assembly3390
Remove and Install Work Equipment Assembly3394
Remove Work Equipment Assembly3394
Install Work Equipment Assembly3398
Disassemble and Assemble Stroke Sensing Boom Cylinder Assembly3404
How to Disassemble Stroke Sensing Boom Cylinder Assembly3405
How to Assemble Stroke Sensing Boom Cylinder Assembly3410
Disassemble and Assemble Stroke Sensing Arm Cylinder Assembly3417
How to Disassemble Stroke Sensing Arm Cylinder Assembly3418
How to Assemble Stroke Sensing Arm Cylinder Assembly3423
Disassemble and Assemble Stroke Sensing Bucket Cylinder Assembly3432
How to Disassemble Stroke and Reset Sensing Bucket Cylinder Assembly3433
How to Assemble Stroke and Reset Sensing Bucket Cylinder Assembly3438
CAB Related Parts3449
Remove and Install Operator Cab Assembly3449
How to Remove Operator Cab Assembly3449
Install Operator CAB Assembly3458
Remove and Install Operator Cab Glass (Adhered Glass)3466
Remove Operator CAB Glass (Adhered Glass)3468
Install Operator CAB Glass (Adhered Glass)3468
Remove and Install Front Window Assembly3478
Remove Front Window Assembly3478
Install Front Window Assembly3481
Remove and Install Floor Frame Assembly3487
How to Remove Floor Frame Assembly3487
How to Install Floor Frame Assembly3494
Remove and Install Air Conditioner Unit Assembly3502
Remove Air Conditioner Unit Assembly3502
Install Air Conditioner Unit Assembly3508
Remove and Install Operator Seat3515
Remove Operator’s Seat3515
Install Operator’s Seat3517
How to Remove and Install Seat Belt3521
How to Remove Seat Belt3521
How to Install Seatbelt3522
Remove and Install Work Equipment Control Lever Assembly3523
How to Remove Work Equipment Control Lever Assembly3523
How to Install Work Equipment Control Lever Assembly3529
Remove and Install Front Wiper Assembly3538
Remove Front Wiper Assembly3538
Install Front Wiper Assembly3544
Electrical System3553
Remove and Install Engine Controller Assembly3553
Remove Engine Controller Assembly3553
Install Engine Controller Assembly3554
Remove and Install Pump Controller Assembly3556
Remove Pump Controller Assembly3556
Install Pump Controller Assembly3560
Remove and Install Work Equipment Controller Assembly3566
Remove Work Equipment Controller Assembly3566
Install Work Equipment Controller Assembly3567
Remove and Install Machine Monitor Assembly3570
Remove Machine Monitor Assembly3570
Install Machine Monitor Assembly3573
Remove and Install Pump Swash Plate Sensor3577
Remove Pump Swash Plate Sensor3577
Install Pump Swash Plate Sensor3578
Remove and Install Mass Air Flow and Temperature Sensor3579
How to Remove Mass Air Flow and Temperature Sensor3579
How to Install Mass Air Flow and Temperature Sensor3580
Remove and Install KCCV Crankcase Pressure Sensor3582
How to Remove KCCV Crankcase Pressure Sensor3582
How to Install KCCV Crankcase Pressure Sensor3583
Remove and Install SCR Temperature Sensor3585
Remove SCR Temperature Sensor3585
Install SCR Temperature Sensor3587
Remove and Install Gateway Function Controller Assembly3589
Remove Gateway Function Controller Assembly3589
How to Install Gateway Function Controller Assembly3594
Remove and Install Communication Terminal Wiring Harness3599
Remove Communication Terminal Wiring Harness3599
Install Communication Terminal Wiring Harness3607
Remove and Install Communication Terminal3616
Remove Communication Terminal3616
Install Communication Terminal3618
Remove and Install ICT Sensor Controller Assembly3621
Remove ICT Sensor Controller Assembly3621
Install ICT Sensor Controller Assembly3623
Remove and Install Junction Harness of Control Box3626
How to Remove Junction Harness of Control Box3626
How to Install Junction Harness of Control Box3628
Remove and Install Control Box Harness3630
Remove Control Box Harness3630
Install Control Box Harness3631
Remove and Install GNSS Receiver3633
Remove GNSS Receiver3633
Install GNSS Receiver3634
Remove and Install GNSS Receiver Antenna3635
How to Remove GNSS Receiver Antenna3635
How to Install GNSS Receiver Antenna3635
Remove and Install Network Modem Antenna3637
Remove Network Modem Antenna3637
Install Network Modem Antenna3637
Remove and Install GNSS Antenna3639
Remove GNSS Antenna3639
Install GNSS Antenna3640
Remove and Install IMU Sensor3641
Remove IMU Sensor3641
Install IMU Sensor3641
60 Maintenance Standard3645
Table of Contents3646
Engine and Cooling System3647
Maintenance Standard for Engine Mount3647
Maintenance Standard for Cooling System3648
Maintenance Standard for Cooling Fan Pump3649
Maintenance Standard for Servo Valve3650
Maintenance Standard for Cooling Fan Motor3651
Power Train3652
Maintenance Standard for Swing Circle3652
Maintenance Standard for Swing Machinery3653
Maintenance Standard for Final Drive3655
Maintenance Standard for Sprocket3657
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing3658
Undercarriage and Frame3659
Maintenance Standard for Track Frame and Idler Cushion3659
Maintenance Standard for Idler3661
Maintenance Standard for Track Roller3663
Maintenance Standard for Carrier Roller3665
Maintenance Standard for Track Shoes3666
Maintenance Standard for Triple Shoes3669
Hydraulic System3670
Maintenance Standard for Main Pump3670
Maintenance Standard for Swing Motor3672
Maintenance Standard for Travel Motor3675
Maintenance Standard for Control Valve3678
Maintenance Standard for Work Equipment and Swing PPC Valve3689
Maintenance Standard for Travel PPC Valve3692
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)3695
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve3696
Maintenance Standard for Solenoid Valve3698
Maintenance Standard for Attachment Circuit Selector Valve3699
Maintenance Standard for Center Swivel Joint3700
Work Equipment3701
Maintenance Standard for Work Equipment Linkage3701
Dimensions of Arm3706
Dimensions of Bucket3708
Maintenance Standard for Boom Cylinder3710
Maintenance Standard for Stroke Sensing Boom Cylinder3711
Maintenance Standard for Stroke Sensing Arm Cylinder3713
Maintenance Standard for Stroke and Reset Sensing Bucket Cylinder3714
Maintenance Standard for Stroke Sensor for Boom Cylinder3715
Maintenance Standard for Stroke Sensor for Arm Cylinder3716
Maintenance Standard for Stroke and Reset Sensor for Bucket Cylinder3717
80 Appendix3719
Table of Contents3720
Precautions Before Work3722
Air Conditioner System3723
Precautions for Refrigerant3723
Air Conditioner Component3724
Specifications of Air Conditioner3726
Structure and Function of Refrigeration Cycle3727
Outline of Refrigeration Cycle3728
Component Parts of Air Conditioner System3730
Air Conditioner Unit3730
Configuration Diagram of Air Conditioner Unit3730
Function of Air Conditioner Unit3732
Component Parts of Air Conditioner Unit3734
Function of Evaporator as Air Conditioner Unit Component3735
Function of Heater Core as Air Conditioner Unit Component3735
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component3735
Function of Servo Motor as Air Conditioner Unit Component3735
Structure of Expansion Valve as Air Conditioner Unit Component3736
Function of Expansion Valve as Air Conditioner Unit Component3736
Operate Expansion Valve as Air Conditioner Unit Component3736
Function of Dual Pressure Switch3737
Air Conditioner Controller3738
Structure of Air Conditioner Controller3738
Compressor3739
Structure of Compressor3739
Specifications of Compressor3739
Function of Compressor3739
Condenser3740
Structure of Condenser3740
Specifications of Condenser3740
Function of Condenser3740
Receiver Drier3741
Structure of Receiver Dryer3741
Specifications of Receiver Dryer3741
Function of Receiver Dryer3741
Air Conditioner Related Sensors3742
Structure of Sunlight Sensor3742
Function of Sunlight Sensor3742
Structure of Outside Temperature Sensor3742
Function of Outside Air Temperature Sensor3742
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner3744
Circuit Diagram and Configuration of Connector Pins of Air Conditioner3746
System Diagram of Air Conditioner3748
Input and Output Signals of Air Conditioner Controller3749
Function of Air Conditioner Controller3750
Locations of Air Conditioner Parts and Layout of Connectors3751
Examine Air Leakage (Duct)3755
How to Examine Air Leakage (Duct)3755
Examine Air Conditioner with Self-Diagnosis Function3756
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor3757
Examine Vent (Mode) Changeover3758
How to Examine Vent (Mode) Changeover3758
Examine Fresh/Recirc Air Changeover3759
How to Examine Fresh/Recirc Air Changeover3759
Examine Sunlight Sensor3760
How to Examine Sunlight Sensor3760
Examine Refrigerant (Dual) Pressure Switch3761
How to Examine Refrigerant (Dual) Pressure Switch3761
Examine Relay3762
How to Examine Relay3762
Air Conditioner Troubleshooting Chart 13763
Air Conditioner Troubleshooting Chart 23764
Information Shown in Troubleshooting Table3767
Failure Code [879AKA]3768
Failure Code [879AKB]3769
Failure Code [879BKA]3770
Failure Code [879BKB]3772
Failure Code [879CKA]3774
Failure Code [879CKB]3775
Failure Code [879DKZ]3776
Failure Code [879EMC]3778
Failure Code [879FMC]3779
Failure Code [879GKX]3780
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)3782
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)3783
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)3784
A-4 Troubleshooting for Fresh/Recirc Air Changeover3785
Troubleshooting by Gauge Pressure3786
Connect Service Tool3789
How to Connect Service Tool3789
Precautions for Disconnection and Connection of Air Conditioner Piping3791
Handle Compressor Oil3793
90 Circuit Diagrams3795
Table of Contents3796
Hydraulic Circuit Diagram3797
Symbols Used in Hydraulic Circuit Diagram3797
Hydraulic Circuit Diagram (1/2)3801
Hydraulic Circuit Diagram (2/2)3803
Electrical Circuit Diagram3805
Symbols Used in Electric Circuit Diagram3805
Electrical Circuit Diagram (1/13)3809
Electrical Circuit Diagram (2/13)3811
Electrical Circuit Diagram (3/13)3813
Electrical Circuit Diagram (4/13)3815
Electrical Circuit Diagram (5/13)3817
Electrical Circuit Diagram (6/13)3819
Electrical Circuit Diagram (7/13)3821
Electrical Circuit Diagram (8/13)3823
Electrical Circuit Diagram (9/13)3825
Electrical Circuit Diagram (10/13)3827
Electrical Circuit Diagram (11/13)3829
Electrical Circuit Diagram (12/13)3831
Electrical Circuit Diagram (13/13)3833
Electrical Circuit Diagram (1/14) (Multi GNSS Support, 104 inch Display)3835
Electrical Circuit Diagram (2/14) (Multi GNSS Support, 104 inch Display)3837
Electrical Circuit Diagram (3/14) (Multi GNSS Support, 104 inch Display)3839
Electrical Circuit Diagram (4/14) (Multi GNSS Support, 104 inch Display)3841
Electrical Circuit Diagram (5/14) (Multi GNSS Support, 104 inch Display)3843
Electrical Circuit Diagram (6/14) (Multi GNSS Support, 104 inch Display)3845
Electrical Circuit Diagram (7/14) (Multi GNSS Support, 104 inch Display)3847
Electrical Circuit Diagram (8/14) (Multi GNSS Support, 104 inch Display)3849
Electrical Circuit Diagram (9/14) (Multi GNSS Support, 104 inch Display)3851
Electrical Circuit Diagram (10/14) (Multi GNSS Support, 104 inch Display)3853
Electrical Circuit Diagram (11/14) (Multi GNSS Support, 104 inch Display)3855
Electrical Circuit Diagram (12/14) (Multi GNSS Support, 104 inch Display)3857
Electrical Circuit Diagram (13/14) (Multi GNSS Support, 104 inch Display)3859
Electrical Circuit Diagram (14/14) (Multi GNSS Support, 104 inch Display)3861
INDEX3863

S.M 29/12/24