Service manual Komatsu PC138USLC-11 50001 & Up | SEN06589-18

Komatsu PC138USLC-11 50001 & Up SEN06589-18 (Preview)

00 Index and Foreword
Index
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Engine Technology to Conform Exhaust Gas Emission
Precautions for DEF
General Character and Precautions for Handling
Precautions for Adding
Precautions for Storage
Precautions for Fire Hazard and Leakage
Other Precautions
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
How to Disconnect and Connect Type 1 Push-Pull Type Coupler
How to Disconnect and Connect Type 2 Push-Pull Type Coupler
How to Disconnect and Connect Type 3 Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table
01 Specifications
Table of Contents
Abbreviation List
Specifications
Specification Drawing
Specification Drawing PC138USLC-11
Working Range Drawings
Working Range Drawings PC138USLC-11
Specifications
Specifications PC138USLC-11
Weight Table
Weight Table PC138USLC-11
Table of Fuel, Coolant, and Lubricants
10 Structure and Function
Table of Contents
Abbreviation List
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Function of DEF System (Applicable Machine: 50001 to 62010)
Function of DEF System (Serial No.:62011 and up)
Inducement Strategy
Function that Calls for Attention of the Operator for Urea SCR System to Stay Functional
Component Parts of Urea SCR System
DEF Mixing Tube
SCR Assembly
DEF Tank
DEF Pump
DEF Injector
DEF Hose
DEF Tank Heating Valve
Boot-up System
Layout Drawing of Boot-Up System (Serial No.: 50001 to 62010)
Layout Drawing of Boot-Up System (Serial No.:62011 and up)
System Operating Lamp System
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal)
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)
Function of System Operating Lamp System (Machine with KOMTRAX Terminal)
Function of System Operating Lamp System (Machine with Gateway Function Controller) (Serial No.: 50001 to 62010)
Function of System Operating Lamp System (Machine with Gateway Function Controller) (Serial No.: 62011 and Up)
Battery Disconnect Switch
Function of Battery Disconnect Switch (Applicable Machine: 50001 to 62010)
Function of Battery Disconnect Switch (Serial No.:62011 and up)
Engine System
Layout Drawing of Engine System
Engine Control System
System Diagram of Engine Control System (Machine with KOMTRAX Terminal)
System Diagram of Engine Control System (Machine with Gateway Function Controller)
Function of Engine Control System (Machine with KOMTRAX Terminal)
Function of Engine Control System (Machine with Gateway Function Controller)
Auto-Deceleration System
System Diagram of Auto-Deceleration System
Function of Auto-Deceleration System
Operation of Auto-Deceleration System
Engine Automatic Warm-up System
System Diagram of Engine Automatic Warm-up System
Function of Engine Automatic Warm-up System
Overheat Prevention System
Function of Overheat Prevention System
Turbocharger Protection System
Function of Turbocharger Protection System
Automatic Idle Stop System
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal)
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller)
Function of Automatic Idle Stop System
Component Parts of Engine System
PTO
Variable Flow Turbocharger
EGR System
EGR Valve
EGR Cooler
KCCV System
KCCV Ventilator
Exhaust Throttle Valve
KDOC
Cooling System
Layout Drawing of Cooling System
Specifications of Cooling System
Control System
Layout Drawing of Control System (Machine with KOMTRAX Terminal)
Layout Drawing of Control System (Machine with Gateway Function Controller)
Machine Monitor System
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal)
System Diagram of Machine Monitor System (Machine with Gateway Function Controller)
Function of Machine Monitor System
KomVision System
Layout Drawing of KomVision System
System Diagram of KomVision System
Function of KomVision System
KOMTRAX System
KOMTRAX System Diagram (Machine with KOMTRAX Terminal)
System Diagram of KOMTRAX System (Machine with Gateway Function Controller)
Function of KOMTRAX System
Component Parts of Control System
Machine Monitor
KomVision Controller
KomVision Camera
KOMTRAX Terminal
Gateway Function Controller
Communication Terminal
Pump Controller
Resistor for PC-EPC Valve
CAN Terminating Resistor
Engine Controller
Fuel Control Dial
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Structure of CLSS
Function of CLSS
Engine and Pump Combined Control System
Engine and Pump Combined Control System Diagram
Function of Engine and Pump Combined Control System
Component Parts of Hydraulic System
Hydraulic Tank
Main Pump
Control Valve
Work Equipment System
Layout Drawing of Work Equipment System
Structure of Valve Control
PPC Lock System
System Diagram of PPC Lock
Function of PPC Lock System
Work Equipment and Travel Automatic Lock System
System Diagram of Lock Lever Automatic Lock System
Function of Work Equipment and Travel Automatic Lock System
Operation of Lock Lever Automatic Lock System
Attachment Oil Flow Adjuster System
Attachment Oil Flow Adjuster System Diagram
Function of Attachment Oil Flow Adjuster System
Tool Control System
Tool Control System Diagram
Component Parts of Work Equipment System
Work Equipment and Swing PPC Valve
1st-Line Attachment PPC Valve (with EPC Valve)
Blade PPC Valve
Solenoid Valve
Variable Back Pressure Solenoid Valve
Multi-Control Valve
Arm Dump Quick Return Valve
1st-Line Attachment Variable Relief Valve
Pilot Circuit Accumulator
Attachment Circuit Accumulator (For Low Pressure Circuit)
Swing System
Layout Drawing of Swing System
Swing Control System Diagram
Function of Swing Control System
Component Parts of Swing System
Swing Motor
Swing Machinery
Swing Circle
Travel System
Layout Drawing of Travel System
System Diagram of Travel Control System
Function of Travel Control System
Component Parts of Travel System
Travel Motor
Travel PPC Valve
Center Swivel Joint
Undercarriage and Frame
Layout Drawing of Undercarriage
Specifications of Undercarriage
Idler Cushion
Structure of Idler Cushion
Specifications of Idler Cushion
Work Equipment
Structure of Work Equipment
Function of Work Equipment
Work Equipment Clearance Adjustment Shim
Function of Work Equipment Clearance Adjustment Shim
Bucket Clearance Adjustment Shim
Function of Bucket Clearance Adjustment Shim
CAB Related Parts
ROPS CAB
Structure of ROPS CAB (Machine with KOMTRAX Terminal)
Structure of ROPS CAB (Machine with Gateway Function Controller)
Function of ROPS CAB
CAB Mount
Structure of CAB Mount
Function of CAB Mount
Remove Wiring Harness Out of Cab
20 Standard Value Table
Table of Contents
Abbreviation List
Standard Value Table for Engine
Standard Value Table for Engine: PC138USLC-11
Standard Value Table for Machine
Standard Value Table for Machine: PC138USLC-11
Machine Posture and Procedures to Measure Performance
30 Testing and Adjusting
Table of Contents
Precautions Before Work
Abbreviation List
Related Information on Testing and Adjusting
Differences In Machine Monitor Symbols
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
How to Examine Engine Speed
Examine Exhaust Gas Color
How to Examine Exhaust Gas Color with the Handy Smoke Checker
How to Examine Exhaust Gas Color with Smoke Meter
Examine the Clearance of Exhaust Throttle Valve
How to Measure Clearance of the Exhaust Throttle Valve
Examine and Adjust Valve Clearance
How to Examine Valve Clearance
How to Adjust Valve Clearance
Examine Compression Pressure
How to Examine Compression Pressure
Examine Blowby Pressure
How to Examine Blowby Pressure
Examine Engine Oil Pressure
How to Examine Engine Oil Pressure
Visual Check Inside of EGR Valve
How to do the Visual Check Inside of EGR Valve
Clean Inside of EGR Valve
How to Clean Inside of EGR Valve
Examine Fuel Pressure
How to Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
How to Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
How to Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
How to Examine Fuel System for Leakage
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine and Adjust Air Conditioner Compressor Belt Tension
How to Examine Air Conditioner Compressor Belt
How to Adjust Air Conditioner Compressor Belt
Examine Alternator Belt
How to Examine Alternator Belt
Examine Automatic Tensioner
How to Examine Automatic Tensioner
Examine Cooling Fan Speed
How to Examine Cooling Fan Speed
Write Injector Compensation Value to Engine Controller
How to Write Injector Compensation Value
Examine SCR Related Functions
Examine DEF Pump Raised Pressure
Examine Injection Volume from DEF Injector
Examine DEF Line Heater Relay 1
Examine DEF Line Heater Relay 2
Examine DEF Pump Heater Relay
Examine DEF Tank Heater Valve
Examine SCR Denitration Efficiency
Clean DEF Tank
How to Clean DEF Tank
Bleed Air from Coolant Circuit of DEF Tank
How to Bleed Air from Coolant Circuit of DEF Tank
Clean DEF Pump
How to Clean DEF Pump
Power Train
Examine Swing Circle Bearing Clearance
How to Examine Swing Circle Bearing Clearance
Undercarriage and Frame
Examine and Adjust Track Tension
How to Examine Track Tension
How to Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
How to Release Remained Pressure from Hydraulic Tank
How to Release Remained Pressure in Hydraulic Cylinder Circuit
How to Release Remained Pressure from Swing Motor Circuit
How to Release Remained Pressure from Travel Motor Circuit
Examine and Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits
How to Examine Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits
How to Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits
Examine Oil Pressure of Control Circuit
How to Examine Oil Pressure in Control Circuit
Examine and adjust oil pressure in pump PC control circuit
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)
How to Examine PC-EPC Valve Outlet Pressure
How to Adjust Oil Pressure in Pump PC Control Circuit
Examine and Adjust Oil Pressure in Pump LS Control Circuit
How to Examine LS Differential Pressure with Machine Monitor
How to Examine LS Differential Pressure by Testing Tool
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure)
How to Adjust LS Valve
Examine Outlet Pressure of Solenoid Valve
How to Examine Outlet Pressure of Solenoid Valve
Operating Condition of Solenoid Valve
How to Examine Outlet Pressure in Variable Back Pressure Solenoid Valve
Operating Condition of Variable Back Pressure Solenoid Valve
Examine PPC Valve Outlet Pressure
How to Examine Outlet Pressure in PPC Valve
Examine Attachment Circuit Oil Pressure
How to Examine Attachment Circuit Oil Pressure
Adjust Play of Work Equipment and Swing PPC Valves
How to Adjust Play of Work Equipment and Swing PPC Valves
Examine and Adjust Travel Deviation
How to Examine Travel Deviation
How to Adjust Travel Deviation
Examine Parts Which Cause Hydraulic Drift of Work Equipment
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder
How to Examine Parts that Cause Hydraulic Drift of PPC Valve
Examine Oil Leakage
How to Examine Oil Leakage from Boom Cylinder
How to Examine Oil Leakage from Arm Cylinder
How to Examine Oil Leakage from Bucket Cylinder
How to Examine Oil Leakage from Blade Cylinder
How to Examine Oil Leakage from Swing Motor
How to Examine Oil Leakage from Travel Motor
Bleed Air from Hydraulic Circuit
How to Bleed Air from Hydraulic System
CAB Related Parts
Examine CAB Tipping Stopper
How to Examine Cab Tipping Stopper
How to Adjust Mirrors
Procedure to Adjust Machine Left Front Mirror (A)
Procedure to Adjust Machine Rear Mirror (B)
How to Examine and Adjust Slide Door
How to Examine and Adjust Slide Door When It is Closed and Locked
How to Examine and Adjust Slide Door When It is Open and Locked
Electrical System
Set and Operate Machine Monitor
Operator Mode
Function to Show Technician Identification Status Screen
Function to Show Operator Identification Input Screen
Examine Function by LCD (Liquid Crystal Display)
Examine Function of Service Meter
Usage Limitation and Maintenance Password Change Function
Service Mode
How to Operate Service Mode
How to See Pre-defined Monitoring Information
How to Examine Self-Define Monitor Information
Abnormality Record Menu
How to See Maintenance Record
Maintenance Mode Setting
How to Set Phone Number Entry
Default Menu
Diagnostic Tests Menu
Adjustment Menu
No-Injection Cranking Operation
KOMTRAX Settings Menu
How to Show Service Message
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)
How to Start Up KOMTRAX System (Machine with Gateway Function Controller)
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)
Adjust Rearview Camera Angle
How to Adjust Rearview Camera Angle
Adjust KomVision Camera Angle
How to Adjust KomVision Camera Angle
Adjust KomVision Related Function
Setting of KomVision (Main Setting)
Setting of KomVision (Camera Setting)
Setting of KomVision (Camera Calibration)
Set Region of Bluetooth(R) Compatible Radio
How to Set Region of Bluetooth(R) Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)
Handle Battery Disconnect Switch (Machine with Gateway Function Controller)
Examine Diodes
How to Examine Diodes by Digital Tester
How to Examine Diodes by Analog Tester
Pm Clinic
Pm Clinic Service
Pm Clinic Check Sheet: PC138USLC-11
40 Troubleshooting
Table of Contents
Precautions Before Work
Abbreviation List
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Walk-Around Check
Test in Accordance with Testing Procedure
Examine Fuel Level and Type
Examine Fuel Prefilter
Examine Water Separator, Drain Water and Sediment
How to Replace Fuel Prefilter Cartridge
Examine Fuel Main Filter
Examine Engine Oil Level (Oil Quantity in Oil Pan)
Examine Oil Level in PTO Gear Case
Examine Coolant Level (Reservoir Tank)
Examine Air Cleaner Clogging
Clean Outer Element
Replace Element
Examine Hydraulic Oil Level
Examine Hydraulic Oil Strainer
Examine Hydraulic Oil Filter
Examine Oil Level in Swing Machinery Case
Examine Oil Level in Final Drive Case
Bleed Air from Fuel System
Bleed Air from Hydraulic System
How to Examine Electric Equipment
Preparation for Troubleshooting of Electrical System
Preparation for Troubleshooting of Machine Monitor
Preparation for Troubleshooting of Engine Controller
Preparation for Troubleshooting of Pump Controller
Preparation for Troubleshooting of KOMTRAX Terminal
Preparation for Troubleshooting of Gateway Function Controller
How to Disconnect and Connect Connector with a Special Lock
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
How to Diagnose Wiring Harness for Open Circuit of Pressure Sensor System
Connector List and Layout (Machine with KOMTRAX Terminal)
Connector List and Layout (Machine with Gateway Function Controller)
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Replace KDOC
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
Failure Code [989L00]
Failure Code [989M00]
Failure Code [989N00]
Failure Code [A1U0N3]
Failure Code [A1U0N4]
Failure Code [A900FR]
Failure Code [A900N6]
Failure Code [A900NY]
Failure Code [AA10NX]
Failure Code [AB00KE]
Failure Code [AQ10MB]
Failure Code [AQ10N3]
Failure Code [AS00R2]
Failure Code [AS00R3]
Failure Code [AS00R4]
Failure Code [AS00R5]
Failure Code [AS00R6]
Failure Code [AS00ZK]
Failure Code [AS10KM]
Failure Code [AS10NR]
Failure Code [AS10NT]
Failure Code [AU10QA]
Failure Code [B@BAZG]
Failure Code [B@BAZK]
Failure Code [B@BCNS]
Failure Code [B@HANS]
Failure Code [CA115]
Failure Code [CA122]
Failure Code [CA123]
Failure Code [CA131]
Failure Code [CA132]
Failure Code [CA144]
Failure Code [CA145]
Failure Code [CA153]
Failure Code [CA154]
Failure Code [CA187]
Failure Code [CA221]
Failure Code [CA222]
Failure Code [CA227]
Failure Code [CA234]
Failure Code [CA238]
Failure Code [CA239]
Failure Code [CA249]
Failure Code [CA256]
Failure Code [CA271]
Failure Code [CA272]
Failure Code [CA322]
Failure Code [CA324]
Failure Code [CA331]
Failure Code [CA332]
Failure Code [CA343]
Failure Code [CA351]
Failure Code [CA352]
Failure Code [CA356]
Failure Code [CA357]
Failure Code [CA386]
Failure Code [CA435]
Failure Code [CA441]
Failure Code [CA442]
Failure Code [CA449]
Failure Code [CA451]
Failure Code [CA452]
Failure Code [CA515]
Failure Code [CA516]
Failure Code [CA553]
Failure Code [CA555]
Failure Code [CA556]
Failure Code [CA559]
Failure Code [CA689]
Failure Code [CA691]
Failure Code [CA692]
Failure Code [CA697]
Failure Code [CA698]
Failure Code [CA731]
Failure Code [CA778]
Failure Code [CA1117]
Failure Code [CA1664]
Failure Code [CA1669]
Failure Code [CA1673]
Failure Code [CA1677]
Failure Code [CA1678]
Failure Code [CA1682]
Failure Code [CA1683]
Failure Code [CA1684]
Failure Code [CA1686]
Failure Code [CA1691]
Failure Code [CA1694]
Failure Code [CA1695]
Failure Code [CA1696]
Failure Code [CA1712]
Failure Code [CA1713]
Failure Code [CA1714]
Failure Code [CA1715]
Failure Code [CA1776]
Failure Code [CA1777]
Failure Code [CA1843]
Failure Code [CA1844]
Failure Code [CA1885]
Failure Code [CA1887]
Failure Code [CA1896]
Failure Code [CA1938]
Failure Code [CA1942]
Failure Code [CA1961]
Failure Code [CA2185]
Failure Code [CA2186]
Failure Code [CA2249]
Failure Code [CA2272]
Failure Code [CA2311]
Failure Code [CA2349]
Failure Code [CA2353]
Failure Code [CA2357]
Failure Code [CA2636]
Failure Code [CA2637]
Failure Code [CA2765]
Failure Code [CA2771]
Failure Code [CA2976]
Failure Code [CA3142]
Failure Code [CA3143]
Failure Code [CA3144]
Failure Code [CA3146]
Failure Code [CA3147]
Failure Code [CA3148]
Failure Code [CA3151]
Failure Code [CA3165]
Failure Code [CA3229]
Failure Code [CA3231]
Failure Code [CA3232]
Failure Code [CA3235]
Failure Code [CA3239]
Failure Code [CA3241]
Failure Code [CA3242]
Failure Code [CA3251]
Failure Code [CA3313]
Failure Code [CA3314]
Failure Code [CA3315]
Failure Code [CA3419]
Failure Code [CA3421]
Failure Code [CA3497]
Failure Code [CA3498]
Failure Code [CA3543]
Failure Code [CA3545]
Failure Code [CA3547]
Failure Code [CA3558]
Failure Code [CA3559]
Failure Code [CA3562]
Failure Code [CA3563]
Failure Code [CA3567]
Failure Code [CA3568]
Failure Code [CA3571]
Failure Code [CA3572]
Failure Code [CA3574]
Failure Code [CA3575]
Failure Code [CA3577]
Failure Code [CA3578]
Failure Code [CA3582]
Failure Code [CA3583]
Failure Code [CA3596]
Failure Code [CA3649]
Failure Code [CA3681]
Failure Code [CA3682]
Failure Code [CA3713]
Failure Code [CA3717]
Failure Code [CA3718]
Failure Code [CA3724]
Failure Code [CA3725]
Failure Code [CA3748]
Failure Code [CA3755]
Failure Code [CA3866]
Failure Code [CA3867]
Failure Code [CA3868]
Failure Code [CA3899]
Failure Code [CA3911]
Failure Code [CA3912]
Failure Code [CA3918]
Failure Code [CA3921]
Failure Code [CA3928]
Failure Code [CA3932]
Failure Code [CA3933]
Failure Code [CA3934]
Failure Code [CA3935]
Failure Code [CA3936]
Failure Code [CA4152]
Failure Code [CA4155]
Failure Code [CA4156]
Failure Code [CA4157]
Failure Code [CA4159]
Failure Code [CA4164]
Failure Code [CA4165]
Failure Code [CA4166]
Failure Code [CA4168]
Failure Code [CA4169]
Failure Code [CA4171]
Failure Code [CA4249]
Failure Code [CA4251]
Failure Code [CA4261]
Failure Code [CA4277]
Failure Code [CA4281]
Failure Code [CA4459]
Failure Code [CA4461]
Failure Code [CA4533]
Failure Code [CA4534]
Failure Code [CA4731]
Failure Code [CA4732]
Failure Code [CA4739]
Failure Code [CA4768]
Failure Code [CA4769]
Failure Code [CA4842]
Failure Code [CA4952] (Machine with KOMTRAX Terminal)
Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [CA5115]
Failure Code [CA5179]
Failure Code [CA5181]
Failure Code [CA5271]
Failure Code [CA5272]
Failure Code [CA5273]
Failure Code [CA5274]
Failure Code [CA5275]
Failure Code [CA5276]
Failure Code [CA5277]
Failure Code [CA5387]
Failure Code [CA5388]
Failure Code [CA5389]
Failure Code [CA5391]
Failure Code [CA5392]
Failure Code [CA5393]
Failure Code [CA5394]
Failure Code [CA5395]
Failure Code [CA5396]
Failure Code [CA5631]
Failure Code [CA5938]
Failure Code [D110KB]
Failure Code [D19JKZ]
Failure Code [D811MC] (Machine with KOMTRAX Terminal)
Failure Code [D811MC] (Machine with Gateway Function Controller)
Failure Code [D862KA] (Machine with KOMTRAX Terminal)
Failure Code [D862KA] (Machine with Gateway Function Controller)
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)
Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)
Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)
Failure Code [D8AQKR] (Machine with Gateway Function Controller)
Failure Code [D8G1KT]
Failure Code [D8G6KT]
Failure Code [DA20MC]
Failure Code [DA22KK]
Failure Code [DA25KP]
Failure Code [DA26KP]
Failure Code [DA29KQ]
Failure Code [DA2LKA] (Machine with KOMTRAX Terminal)
Failure Code [DA2LKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [DA2LKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [DA2LKB] (Machine with KOMTRAX Terminal)
Failure Code [DA2LKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [DA2LKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and up)
Failure Code [DA2QKR] (Machine with KOMTRAX Terminal)
Failure Code [DA2QKR] (Machine with Gateway Function Controller)
Failure Code [DA2RKR] (Machine with KOMTRAX Terminal)
Failure Code [DA2RKR] (Machine with Gateway Function Controller)
Failure Code [DAF0KM]
Failure Code [DAF0MB]
Failure Code [DAF0MC]
Failure Code [DAF8KB]
Failure Code [DAF9KQ]
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)
Failure Code [DAFGMC] (Machine with Gateway Function Controller)
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)
Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)
Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)
Failure Code [DAFQKR] (Machine with Gateway Function Controller)
Failure Code [DAZ9KQ]
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal)
Failure Code [DAZQKR] (Machine with Gateway Function Controller)
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)
Failure Code [DB2QKR] (Machine with Gateway Function Controller)
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal)
Failure Code [DB2RKR] (Machine with Gateway Function Controller)
Failure Code [DB90MC]
Failure Code [DBP0KM]
Failure Code [DBP0KT]
Failure Code [DBP5KB]
Failure Code [DBP5KY]
Failure Code [DBPQKR] (Machine with KOMTRAX Terminal)
Failure Code [DBPQKR] (Machine with Gateway Function Controller)
Failure Code [DDNRKA]
Failure Code [DDNRKY]
Failure Code [DDNS00]
Failure Code [DFB1KZ]
Failure Code [DFB2KZ]
Failure Code [DFB3L8]
Failure Code [DFB4L8]
Failure Code [DFB5KZ]
Failure Code [DFB6KZ]
Failure Code [DGH2KA]
Failure Code [DGH2KB]
Failure Code [DHA4KA]
Failure Code [DHPAMA]
Failure Code [DHS3MA]
Failure Code [DHS4MA]
Failure Code [DHS8MA]
Failure Code [DHS9MA]
Failure Code [DHSAMA]
Failure Code [DHSBMA]
Failure Code [DHSCMA]
Failure Code [DHSDMA]
Failure Code [DHSFMA]
Failure Code [DHSGMA]
Failure Code [DHSHMA]
Failure Code [DHSJMA]
Failure Code [DHSKMA]
Failure Code [DHSLMA]
Failure Code [DKULKA]
Failure Code [DKULKB]
Failure Code [DKULKY]
Failure Code [DLM5KA]
Failure Code [DLM5MB]
Failure Code [DR10KA]
Failure Code [DR12KA]
Failure Code [DR20KA]
Failure Code [DR21KX]
Failure Code [DR40KA]
Failure Code [DUMBKA] (Machine with KOMTRAX Terminal)
Failure Code [DUMBKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [DUMBKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [DUMBKB] (Machine with KOMTRAX Terminal)
Failure Code [DUMBKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)
Failure Code [DUMBKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)
Failure Code [DV20KB]
Failure Code [DW43KA]
Failure Code [DW43KB]
Failure Code [DW43KY]
Failure Code [DW45KA]
Failure Code [DW45KB]
Failure Code [DW45KY]
Failure Code [DW4CKY]
Failure Code [DW91KA]
Failure Code [DW91KB]
Failure Code [DW91KY]
Failure Code [DWA2KA]
Failure Code [DWA2KB]
Failure Code [DWA2KY]
Failure Code [DWJ0KA]
Failure Code [DWJ0KB]
Failure Code [DWJ0KY]
Failure Code [DWK2KA]
Failure Code [DWK2KB]
Failure Code [DWK2KY]
Failure Code [DWN5KA]
Failure Code [DWN5KB]
Failure Code [DWN5KY]
Failure Code [DWNSKA]
Failure Code [DWNSKB]
Failure Code [DWNSKY]
Failure Code [DXA8KA]
Failure Code [DXA8KB]
Failure Code [DXE4KA]
Failure Code [DXE4KB]
Failure Code [DXE4KY]
Failure Code [DXEKKA]
Failure Code [DXEKKB]
Failure Code [DXEKKY]
Failure Code [DY20KA]
Failure Code [DY20MA]
Failure Code [DY2CKB]
Failure Code [DY2DKB]
Failure Code [DY2EKB]
Failure Code [F311KA]
Failure Code [F311KB]
Failure Code [F312KA]
Failure Code [F312KB]
Failure Code [F313KA]
Failure Code [F313KB]
Failure Code [F314KA]
Failure Code [F314KB]
Failure Code [F316KB]
Failure Code [F316KY]
Failure Code [F318KB]
Failure Code [F318KY]
Failure Code [F31AKB]
Failure Code [F31AKY]
Failure Code [F31BKB]
Failure Code [F31BKY]
Failure Code [F31CKB]
Failure Code [F31CKY]
Failure Code [F31DKB]
Failure Code [F31DKY]
Failure Code [F31EKB]
Failure Code [F31EKY]
Failure Code [FS10ZE]
Troubleshooting of Electrical System (E-Mode)
Engine Does Not Start (Engine Does Not Crank)
Manual Preheating System Does Not Operate
While Preheating is in Operation, Preheating Monitor Does Not Come On
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation
Charge Level Monitor Comes On in Red While Engine is in Operation
Fuel Level Monitor Comes On in Red While Engine is in Operation
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation
Fuel Gauge Does Not Move from Minimum or Maximum
Display of Fuel Gauge is Different from Actual Fuel Level
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature
DEF Level is Not Shown Correctly
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature
Some Areas of Machine Monitor Screen are Not Shown
Function Switch Does Not Operate
Automatic Warm-up System Does Not Operate (in Cold Weather)
When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Light Up or Does Not Go Off
Auto-Decelerator is Not Operated or Canceled with Lever
Working Mode Selector Screen is Not Shown While Working Mode Switch is Operated
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated
Travel Speed Does Not Change Even When You Change Travel Speed
Alarm Buzzer Does Not Stop
Service Meter is Not Shown While Starting Switch is in OFF Position
Service Mode Cannot be Selected
All Work Equipment, Swing, Travel Do Not Operate
All Work Equipment, Swing, Travel Cannot be Locked
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position
Travel Alarm Does Not Operate During Travel
Travel Alarm Does Not Stop When Machine Stops
Horn Does Not Sound
Horn Does Not Stop
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated
Windshield Wiper Does Not Operate When Wiper Switch is Operated
When Window Washer Switch is Operated, Window Washer Does Not Operate
“Boom Raise” is Not Shown Correctly with Monitoring Function
“Boom Lower” is Not Shown Correctly with Monitoring Function
“Arm OUT” is Not Shown Correctly with Monitoring Function
“Arm IN” is Not Shown Correctly with Monitoring Function
Bucket DUMP is Not Shown Correctly with Monitoring Function
Bucket CURL is Not Shown Correctly with Monitoring Function
Swing is Not Shown Correctly with Monitoring Function
Travel Indicator is Not Displayed Properly with Monitoring Function
Service is Not Shown Correctly with Monitoring Function
Blade RAISE is Not Shown Correctly with Monitoring Function
Blade LOWER is Not Shown Correctly with Monitoring Function
KOMTRAX System Does Not Operate Correctly
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Information Shown in Troubleshooting Table (H-Mode)
Failure Mode and Cause Table
All Work Equipment, Swing and Travel Do Not Work
All Work Equipment and Travel Speeds are Low or Power is Low
Fine Control Performance or Response is Unsatisfactory
Unusual Noise is Heard from Around Hydraulic Pump
Engine Speed Drops Largely or Engine Stops
Boom Speed or Power is Low
Arm Speed or Power is Low
Bucket Speed or Power is Low
Blade Speed or Power is Low
Work Equipment Does Not Move in Single Operation
Hydraulic Drift of Boom is Large
Hydraulic Drift of Arm is Large
Hydraulic Drift of Bucket is Large
Hydraulic Drift of Blade is Large
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves
Time Lag of Work Equipment is Large
Attachment Circuit Cannot be Changed
Oil Flow in Attachment Circuit Cannot be Changed
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower
In Mixed Operation of Swing and Travel, Travel Speed Falls Largely
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low
Machine Does Not Travel Straight
Machine is Not Steered Well or Steering Power is Low
Travel Speed is Low
One of Tracks Does Not Run
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast
Upper Structure Does Not Swing in Two Directions of Right and Left
Machine Swings Only in One Direction
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left
Swing Acceleration or Swing Speed is Low in Only One Direction
Upper Structure Overruns Excessively When It Stops Swinging (Both Right and Left)
Upper Structure Overruns Excessively When It Stops Swinging (Only One Direction Either Right or Left)
Shock is Large When Upper Structure Stops Swing Operation
Large Unusual Noise is Made When Upper Structure Stops Swing Operation
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)
Swing Drift on a Slope is Large (While Swing Parking Brake is Released)
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
Unusual Noise is Heard from Around Fan
Troubleshooting of Engine (S-Mode)
Information Shown in Troubleshooting Table (S-Mode)
Engine Does Not Crank When Starting Switch is Turned to Start Position
Engine Cranks but No Exhaust Smoke Comes Out
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
Engine Startability is Unsatisfactory
Engine Does Not Pick Up Smoothly
Engine Stops During Operation
Engine Does Not Rotate Smoothly
Engine Lacks Output (or Lacks Power)
Exhaust Smoke is Black
Engine Oil Consumption is Excessive
Engine Oil Becomes Dirty Quickly
Fuel Consumption is Excessive
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
Engine Oil Pressure Drops
Fuel Mixes Into Engine Oil
Water Mixes Into Engine Oil (Milky)
Coolant Temperature Increases Too High (Overheat)
Unusual Noise is Heard
Vibration is Excessive
Air Cannot be Bled from Fuel Circuit
Active Regeneration is Done Frequently
Active Regeneration Continues Long
White Smoke is Exhausted During Active Regeneration
DEF Consumption is Excessive
There is an Unusual Smell (Irritating Odor)
Foreign Materials Enter DEF (DEF Increases)
50 Disassembly and Assembly
Table of Contents
Precautions Before Work
Abbreviation List
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly (When Counterweight Assembly is Not Removed)
How to Remove Supply Pump Assembly (When Counterweight Assembly is Not Removed)
How to Install Supply Pump Assembly (When Counterweight Assembly is Not Removed)
Remove and Install Supply Pump Assembly (When Counterweight Assembly is Removed)
How to Remove Supply Pump Assembly (When Counterweight Assembly is Removed)
How to Install Supply Pump Assembly (When Counterweight Assembly is Removed)
Remove and Install Injector Assembly
How to Remove Injector Assembly
How to Install Injector Assembly
Remove and Install Cylinder Head Assembly
How to Remove Cylinder Head Assembly
How to Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
How to Remove EGR Valve Assembly
How to Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
How to Remove EGR Cooler Assembly
How to Install EGR Cooler Assembly
Remove and Install Starter Assembly
How to Remove Starting Motor Assembly
How to Install Starting Motor Assembly
Remove and Install Air Conditioner Compressor Belt
How to Remove Air Conditioner Compressor Belt
How to Install Air Conditioner Compressor Belt
Remove and Install Alternator Belt
How to Remove Alternator Belt
How to Install Alternator Belt
Remove and Install Automatic Tensioner
How to Remove Automatic Tensioner
How to Install Automatic Tensioner
Remove and Install Radiator Assembly
How to Remove Radiator Assembly
How to Install Radiator Assembly
Remove and Install Hydraulic Oil Cooler Assembly
How to Remove Hydraulic Oil Cooler Assembly
How to Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
How to Remove Aftercooler Assembly
How to Install Aftercooler Assembly
Remove and Install Fan Clutch Assembly
How to Remove Fan Clutch Assembly
How to Install Fan Clutch Assembly
Remove and Install Engine and Main Pump Assembly
How to Remove Engine and Main Pump Assembly
How to Install Engine and Main Pump Assembly
Remove and Install Engine Front Oil Seal
How to Remove Engine Front Oil Seal
How to Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
How to Remove Engine Rear Oil Seal
How to Install Engine Rear Oil Seal
Remove and Install Fuel Cooler Assembly
How to Remove Fuel Cooler Assembly
How to Install Fuel Cooler Assembly
Remove and Install KDOC Assembly
How to Remove KDOC Assembly
How to Install KDOC Assembly
Remove and Install KDOC and SCR Assembly
How to Remove KDOC and SCR Assembly
How to Install KDOC and SCR Assembly
Remove and Install Fuel Tank Assembly
How to Remove Fuel Tank Assembly
How to Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
How to Remove DEF Tank Assembly
How to Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
How to Remove DEF Tank Sensor Flange Assembly
How to Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
How to Remove DEF Tank Sensor
How to Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
How to Remove DEF Tank Strainer
How to Install DEF Tank Strainer
Remove and Install SCR Assembly
How to Remove SCR Assembly
How to Install SCR Assembly
Remove and Install KDOC and SCR Assembly Bracket
How to Remove KDOC and SCR Assembly Bracket
How to Install KDOC and SCR Assembly Bracket
Remove and Install Bellows Pipe Assembly
How to Remove Bellows Pipe Assembly
How to Install Bellows Pipe Assembly
Remove and Install KCCV Assembly
How to Remove KCCV Assembly
How to Install KCCV Assembly
Remove and Install Exhaust Throttle Valve
How to Remove Exhaust Throttle Valve
How to Install Exhaust Throttle Valve
Remove and Install DEF Mixing Tube
How to Remove DEF Mixing Tube
How to Install DEF Mixing Tube
Remove and Install DEF Injector
How to Remove DEF Injector
How to Install DEF Injector
Remove and Install DEF Pump
How to Remove DEF Pump
How to Install DEF Pump
Remove and Install DEF Hose
How to Remove DEF Hose
How to Install DEF Hose
Remove and Install Air Cleaner Assembly
How to Remove Air Cleaner Assembly
How to Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
How to Remove Air Conditioner Compressor Assembly
How to Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
How to Remove Air Conditioner Condenser Assembly
How to Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Travel Motor and Final Drive Assembly
How to Remove Travel Motor and Final Drive Assembly
How to Install Travel Motor and Final Drive Assembly
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and up)
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and Up)
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and Up)
Remove and Install Swing Motor and Swing Machinery Assembly
How to Remove Swing Motor and Swing Machinery Assembly
How to Install Swing Motor and Swing Machinery Assembly
Disassemble and Assemble Swing Machinery Assembly
How to Disassemble Swing Machinery Assembly
How to Assemble Swing Machinery Assembly
Remove and Install Swing Circle Assembly
How to Remove Swing Circle Assembly
How to Install Swing Circle Assembly
Undercarriage and Frame
Separate and Connect Track Assembly
How to Separate Track Assembly
How to Install Track Assembly
Remove and Install Sprocket
How to Remove Sprocket
How to Install Sprocket
Remove and Install Idler and Idler Cushion Assembly
How to Remove Idler and Idler Cushion Assembly
How to Install Idler and Idler Cushion Assembly
Disassemble and Assemble Idler Assembly
How to Disassemble Idler Assembly
How to Assemble Idler Assembly
Disassemble and Assemble Idler Cushion Assembly
How to Disassemble Idler Cushion Assembly
How to Assemble Idler Cushion Assembly
Disassemble and Assemble Track Roller Assembly
How to Disassemble Track Roller Assembly
How to Assemble Track Roller Assembly
Remove and Install Revolving Frame Assembly
How to Remove Revolving Frame Assembly
How to Install Revolving Frame Assembly
Remove and Install Counterweight Assembly
How to Remove Counterweight Assembly
How to Install Counterweight Assembly
Hydraulic System
Remove and Install Center Swivel Joint Assembly
How to Remove Center Swivel Joint Assembly
How to Install Center Swivel Joint Assembly
Disassemble and Assemble Center Swivel Joint Assembly
How to Disassemble Center Swivel Joint Assembly
How to Assemble Center Swivel Joint Assembly
Remove and Install Hydraulic Tank Assembly
How to Remove Hydraulic Tank Assembly
How to Install Hydraulic Tank Assembly
Remove and Install Main Pump Assembly
How to Remove Main Pump Assembly
How to Install Main Pump Assembly
Remove and Install Control Valve Assembly
How to Remove Control Valve Assembly
How to Install Control Valve Assembly
Disassemble and Assemble Control Valve Assembly
How to Assemble Control Valve Assembly
How to Replace Pressure Reducing Valve Cartridge Assembly
Disassemble and Assemble Work Equipment PPC Valve Assembly
How to Disassemble Work Equipment PPC Valve Assembly
How to Assemble Work Equipment PPC Valve Assembly
Disassemble and Assemble Travel PPC Valve Assembly
How to Disassemble Travel PPC Valve Assembly
How to Assemble Travel PPC Valve Assembly
Work Equipment
Remove and Install Blade Assembly
How to Remove Blade Assembly
How to Install Blade Assembly
Remove and Install Work Equipment Assembly
How to Remove Work Equipment Assembly
How to Install Work Equipment Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
How to Disassemble Work Equipment Cylinder Assembly
How to Assemble Work Equipment Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
How to Remove Operator Cab Assembly
How to Install Operator Cab Assembly
Remove and Install Slide Door
How to Remove Slide Door
How to Install Slide Door
Remove and Install Operator Cab Glass (Adhered Glass)
How to Remove Operator Cab Glass (Adhered Glass)
How to Install Operator Cab Glass (Adhered Glass)
Remove and Install Front Window Assembly
How to Remove Front Window Assembly
How to Install Front Window Assembly
Remove and Install Floor Frame Assembly
How to Remove Floor Frame Assembly
How to Install Floor Frame Assembly
Remove and Install Air Conditioner Unit Assembly
How to Remove Air Conditioner Unit Assembly
How to Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove Operator Seat
How to Install Operator Seat
How to Remove and Install Seat Belt
How to Remove Seat Belt
How to Install Seat Belt
Remove and Install Work Equipment Control Lever Assembly
How to Remove Work Equipment Control Lever Assembly
How to Install Work Equipment Control Lever Assembly
Remove and Install Front Wiper Assembly
How to Remove Front Wiper Assembly
How to Install Front Wiper Assembly
Electrical System
Remove and Install Engine Controller Assembly
How to Remove Engine Controller Assembly
How to Install Engine Controller Assembly
Remove and Install Pump Controller Assembly
How to Remove Pump Controller Assembly
How to Install Pump Controller Assembly
Remove and Install KomVision Controller Assembly
How to Remove KomVision Controller Assembly
How to Install KomVision Controller Assembly
Remove and Install Machine Monitor Assembly
How to Remove Machine Monitor Assembly
How to Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
How to Remove Mass Air Flow and Temperature Sensor
How to Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
How to Remove KCCV Crankcase Pressure Sensor
How to Install KCCV Crankcase Pressure Sensor
Remove and Install SCR Temperature Sensor
How to Remove SCR Temperature Sensor
How to Install SCR Temperature Sensor
Remove and Install Rearview Camera
How to Remove Rearview Camera
How to Install Rearview Camera
Remove and Install KomVision Camera
How to Remove KomVision Camera
How to Install KomVision Camera
Remove and Install KOMTRAX Terminal Assembly
How to Remove KOMTRAX Terminal Assembly
How to Install KOMTRAX Terminal Assembly
Remove and Install Gateway Function Controller Assembly
How to Remove Gateway Function Controller Assembly
How to Install Gateway Function Controller Assembly
Remove and Install Communication Terminal Wiring Harness
How to Remove Communication Terminal Wiring Harness
How to Install Communication Terminal Wiring Harness
Remove and Install Communication Terminal
How to Remove Communication Terminal
How to Install Communication Terminal
60 Maintenance Standard
Table of Contents
Abbreviation List
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for PTO
Maintenance Standard for Cooling System
Power Train
Maintenance Standard for Swing Circle
Maintenance Standard for Swing Machinery
Maintenance Standard for Sprocket
Undercarriage and Frame
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Triple Shoes
Maintenance Standard for Road Liner
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Main Pump
Maintenance Standard for PC-EPC Valve
Maintenance Standard for Swing Motor
Maintenance Standard for Travel Motor (Applicable Machine: 50001 to 54383)
Maintenance Standard for Travel Motor (Applicable Machine: 54384 and up)
Maintenance Standard for Control Valve
Maintenance Standard for Work Equipment and Swing PPC Valve
Maintenance Standard for Blade PPC Valve
Maintenance Standard for Travel PPC Valve
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve
Maintenance Standard for Solenoid Valve
Maintenance Standard for Variable Back Pressure Solenoid Valve
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit)
Maintenance Standard for Center Swivel Joint
Work Equipment
Maintenance Standard for Work Equipment Linkage
Dimensions of Arm
Dimensions of Bucket
Maintenance Standard for Boom Cylinder
Maintenance Standard for Arm Cylinder
Maintenance Standard for Bucket Cylinder
Maintenance Standard for Blade Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount
80 Appendix
Table of Contents
Precautions Before Work
Abbreviation List
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Configuration Diagram of Air Conditioner Unit
Function of Air Conditioner Unit
Component Parts of Air Conditioner Unit
Function of Evaporator as Air Conditioner Unit Component
Function of Heater Core as Air Conditioner Unit Component
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component
Function of Servo Motor as Air Conditioner Unit Component
Structure of Expansion Valve as Air Conditioner Unit Component
Function of Expansion Valve as Air Conditioner Unit Component
Operate Expansion Valve as Air Conditioner Unit Component
Function of Dual Pressure Switch
Air Conditioner Controller
Structure of Air Conditioner Controller
Compressor
Structure of Compressor
Specifications of Compressor
Function of Compressor
Condenser
Structure of Condenser
Specifications of Condenser
Function of Condenser
Air Conditioner Related Sensors
Structure of Sunlight Sensor
Function of Sunlight Sensor
Structure of Outside Temperature Sensor
Function of Outside Air Temperature Sensor
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Function of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart 1
Air Conditioner Troubleshooting Chart 2
Information Shown in Troubleshooting Table
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
How to Replace Desiccant
90 Circuit Diagrams
Table of Contents
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (Blade Less Specification, Machine with 1st-Line Attachment is Applicable)
Hydraulic Circuit Diagram (Blade Specification, Machine with 1st-Line Attachment is Applicable)
Hydraulic Circuit Diagram (Blade Specification, Machine with 1st-Line Attachment is Applicable and Arm Crane Specification)
Hydraulic Circuit Diagram (Machine with Multi-Control Valve)
Hydraulic Circuit Diagram (Machine with Tool Control System)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/9)
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/9)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (1/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (2/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (3/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (4/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (5/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (6/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (7/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (8/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (9/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (10/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (1/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (2/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (3/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (4/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (5/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (6/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (7/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (8/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (9/10)
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No.: 62011 and up) (10/10)
Index