Service manual Komatsu PC490LC-11 85001 & Up | SEN06738-08

Komatsu PC490LC-11 85001 & Up SEN06738-08 (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
– Specifications
— Specification Drawing
— Specification Drawing: PC490LC-11
— Working Range Drawings
— Working Range: PC490LC-11
— Specifications
— Specifications: PC490LC-11
— Weight Table
— Weight Table: PC490LC-11
— Table of Fuel, Coolant, and Lubricants
10 Structure and Function
– Table of Contents
– Urea SCR System
— Layout Drawing of Urea SCR System (Applicable Machine: 85001 to 86052)
— Layout Drawing of Urea SCR System (Applicable Machine: 86053 to 86205)
— Layout Drawing of Urea SCR System (Applicable Machine: 86206 and up)
— Urea SCR System Diagram
— Function of Urea SCR System
— Function of DEF System (Applicable Machine: 85001 to 86052)
— Function of DEF System (Applicable Machine: 86053 and Up)
— Inducement Strategy
— 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
— System Operating Lamp System
— System Diagram of System Operating Lamp System
— Function of Operation Lamp System
— Operation of System Operating Lamp System
— Battery Disconnect Switch
— Function of Battery Disconnect Switch
– Engine System
— Layout Drawing of Engine System (Applicable Machine: 85001 to 86205)
— Specifications of Engine System (Applicable Machine: 85001 to 86205)
— Function of Engine System (Applicable Machine: 85001 to 86205)
— Layout Drawing of Engine System (Applicable Machine: 86206 and up)
— Specifications of Engine System (Applicable Machine: 86206 and up)
— Function of Engine System (Applicable Machine: 86206 and up)
— Engine Control System
— System Diagram of Engine Control
— Operation of Engine Control System
— 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
— Overheat Prevention System Diagram
— Function of Overheat Prevention System
— Turbocharger Protection System
— System Diagram of Turbocharger Protection System
— Function of Turbocharger Protection System
— Automatic Idle Stop System
— System Diagram of Automatic Idle Stop System
— Function of Automatic Idle Stop System
— Operation of Automatic Idle Stop System
— Component Parts of Engine System
— VGT
— EGR System
— EGR Valve
— EGR Cooler
— KCCV System
— KCCV Ventilator
— KDPF
– Cooling System
— Layout Drawing of Cooling System
— Specifications of Cooling System
— Fan Speed Control System of Hydraulic Fan
— Fan Speed Control System Diagram of Hydraulic Fan
— Function of Fan Speed Control System of Hydraulic Fan
— Engine Output Control System of Hydraulic Fan
— Engine Output Control System Diagram of Hydraulic Fan
— Function of Engine Output Control System of Hydraulic Fan
— Fan Reverse Rotation System of Hydraulic Fan
— Fan Reverse Rotation System Diagram of Hydraulic Fan
— Function of Fan Reverse Rotation System of Hydraulic Fan
— Component Parts of Cooling System
— Cooling Fan Pump
— Cooling Fan Motor
– Control System
— Layout Drawing of Control System
— Machine Monitor System
— System Diagram of Machine Monitor System
— Function of Machine Monitor System
— KomVision Controller
— Structure of KomVision Controller
— Input and Output Signals of KomVision Controller
— KomVision Camera
— Structure of KomVision Camera
— Input and Output Signals of KomVision Camera
— KomVision System
— Layout Drawing of KomVision System
— System Diagram of KomVision System
— Function of KomVision System
— KOMTRAX System
— System Diagram of KOMTRAX System
— Function of KOMTRAX System
— Component Parts of Control System
— Machine Monitor
— Gateway Function Controller
— Communication Terminal
— Pump Controller
— Resistor for PC-EPC Valve
— CAN Terminating Resistor
— Engine Controller
— Fuel Control Dial
— Fuel Feed Pump
— Fuel Feed Pump Switch
– Hydraulic System
— Layout Drawing of Hydraulic System
— CLSS
— Structure of CLSS
— Operation of Unload Valve and LS Pressure
— Pump Swash Plate Angle (Oil Flow) Control
— Pressure Compensation Control
— Engine and Pump Combined Control System
— Engine and Pump Combined Control System Diagram
— Function of Engine and Pump Combined Control System
— Pump and Valve Control System
— Pump and Valve Control System Diagram
— Function of Pump and Valve 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
— One-Touch Power Maximizing System
— System Diagram of One-Touch Power Maximizing System
— Function of One-Touch Power Maximizing System
— Machine Push-up System
— Machine Push-up System Diagram
— Function of Machine Push-up System
— 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
— Function of Tool Control System
— Component Parts of Work Equipment System
— Work Equipment and Swing PPC Valve
— 1st-Line Attachment PPC Valve (with EPC Valve)
— Solenoid Valve
— Boom Anti-drop Valve
— Arm Anti-Drop Valve
— Attachment Circuit Selector Valve (For High Pressure)
— Attachment Circuit Selector Valve (For Low Pressure)
— 1st-Line Attachment Variable Relief Valve
— Attachment Bypass Solenoid Valve
— Pilot Circuit Accumulator
– 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
— Final Drive
— Travel PPC Valve
— Center Swivel Joint
– Undercarriage and Frame
— Layout Drawing of Undercarriage
— Specifications of Undercarriage
– 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
— Function of ROPS CAB
— CAB Mount
— Structure of CAB Mount
— Function of CAB Mount
— CAB Tipping Stopper
— Structure of CAB Tipping Stopper
— Function of CAB Tipping Stopper
20 Standard Value Table
– Table of Contents
– Standard Value Table for Engine
— Standard Value Table for Engine: PC490LC-11
– Standard Value Table for Machine
— Standard Value Table for Machine: PC490LC-11
— Machine Posture and Procedures to Measure Performance
30 Testing and Adjusting
– Table of Contents
– Precautions Before Work
– Related Information on Testing and Adjusting
— 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 Boost Pressure
— How to Examine Boost Pressure on Machine Monitor
— How to Examine Boost Pressure by Testing Tool
— 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 Mass Air Flow and Temperature Sensor
— How to Examine Mass Air Flow and Temperature Sensor
— 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 on Machine Monitor
— How to Examine Engine Oil Pressure by Testing Tool
— Examine EGR Valve and VGT Oil Pressure
— How to Examine EGR Valve and VGT Oil Pressure
— 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 Tension
— How to Adjust Air Conditioner Compressor Belt Tension
— Clean Fuel Doser
— How to Clean Fuel Doser
— Write Injector Compensation Value to Engine Controller
— How to Write Injector Compensation Value
— Correct Soot Accumulation Correction Value by Ash Influence
— How to Correct Soot Accumulation Correction Value by Ash Influence
— 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
— 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 Circuit
— Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits
— How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits
— How to Adjust Oil Pressure in Work Equipment, Swing, and Travel 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
— Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)
— 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 Examine LS-EPC Valve Outlet 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
— Examine PPC Valve Outlet Pressure
— How to Examine Outlet Pressure in PPC Valve
— Adjust Play of Work Equipment and Swing PPC Valves
— How to Adjust Play of Work Equipment and Swing PPC Valves
— Examine Pump Swash Plate Sensor
— How to Examine pump swash plate sensor
— Examine Cooling Fan Speed
— How to Examine Cooling Fan Speed
— Examine Oil Pressure in Fan Pump Circuit
— How to Examine Oil Pressure in Fan Pump Circuit
— Examine Fan Pump EPC Electric Current
— How to Examine Fan Pump EPC Electric Current
— Examine Fan Pump EPC Solenoid Valve Outlet Pressure
— How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure
— 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
— Examine Oil Leakage from Boom Cylinder
— Examine Oil Leakage of Arm Cylinder
— Examine Oil Leakage of Bucket Cylinder
— How to Examine Oil Leakage of Swing Motor
— How to Examine Oil Leakage of Travel Motor
— Bleed Air from Hydraulic Circuit
— How to Bleed Air from Hydraulic System
— Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side)
— How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side)
— Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)
— How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)
— Replace Accumulator Bladder on High Pressure Side for Attachment Piping
— How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping
– 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 Regular Position of Machine Left Front Mirror (A)
— Procedure to Adjust Machine Right Front Mirror (B)
— Procedure to Adjust Regular Position of Machine Right Front Mirror (B)
— Procedure to Adjust Machine Right Side Mirror (C)
– 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 System
— 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)
— KomVision screen – Check 12 m visibility
— 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
— 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
40 Troubleshooting
– Table of Contents
– Precautions Before Work
– 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 for Impure Ingredient in Fuel
— Examine Fuel Prefilter
— Examine Water Separator, Drain Water and Sediment
— Replace Fuel Prefilter Cartridge
— Examine Fuel Main Filter
— Examine Engine Oil Level (Oil Quantity in Oil Pan)
— 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 Damper 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
— Procedure for Troubleshooting
— Symptom and Troubleshooting Numbers
— Information Shown in Troubleshooting Table
— Connector List and Layout (Applicable Machine: 85001 to 86281)
— CONNECTOR LIST AND LAYOUT (Applicable Machine: 86282 and up)
— Connector Contact Connection Table
— T-Branch Box and T-Branch Adapter Table
— Fuse Location Table
— Precautions When You Clean and Replace KDPF (KCSF and KDOC)
— Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
— 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 [AQ10N3]
— Failure Code [AS00N3]
— 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 [B@BAZG]
— Failure Code [B@BAZK]
— Failure Code [B@BCNS]
— Failure Code [B@BCQA]
— Failure Code [B@BCZK]
— Failure Code [B@HANS]
— Failure Code [CA115]
— Failure Code [CA122]
— Failure Code [CA123]
— Failure Code [CA131]
— Failure Code [CA132]
— Failure Code [CA135]
— Failure Code [CA141]
— 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 [CA273]
— Failure Code [CA274]
— Failure Code [CA322]
— Failure Code [CA323]
— Failure Code [CA324]
— Failure Code [CA325]
— 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 [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 [CA595]
— Failure Code [CA687]
— 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 [CA1879]
— Failure Code [CA1881]
— Failure Code [CA1883]
— Failure Code [CA1885]
— Failure Code [CA1887]
— Failure Code [CA1921]
— Failure Code [CA1922]
— Failure Code [CA1923]
— Failure Code [CA1924]
— Failure Code [CA1925]
— Failure Code [CA1927]
— Failure Code [CA1928]
— Failure Code [CA1942]
— Failure Code [CA1963]
— Failure Code [CA1977]
— Failure Code [CA1993]
— Failure Code [CA2185]
— Failure Code [CA2186]
— Failure Code [CA2249]
— Failure Code [CA2265] (Applicable Machine: 85001 to 86281)
— FAILURE CODE [CA2265] (Applicable Machine: 86282 and up)
— Failure Code [CA2266] (Applicable Machine: 85001 to 86281)
— Failure Code [CA2266] (Applicable Machine: 86282 and up)
— Failure Code [CA2271]
— Failure Code [CA2272]
— Failure Code [CA2349]
— Failure Code [CA2353]
— Failure Code [CA2357]
— Failure Code [CA2381]
— Failure Code [CA2382]
— Failure Code [CA2383]
— Failure Code [CA2386]
— Failure Code [CA2387]
— Troubleshooting Flowchart
— Failure Code [CA2555]
— Failure Code [CA2556]
— Failure Code [CA2637]
— Failure Code [CA2639]
— Failure Code [CA2732]
— Failure Code [CA2733]
— Failure Code [CA2741]
— Failure Code [CA2765]
— Failure Code [CA2771]
— Failure Code [CA2777]
— Failure Code [CA2878]
— Failure Code [CA2881]
— Failure Code [CA2976]
— Failure Code [CA3133]
— Failure Code [CA3134]
— Failure Code [CA3135]
— 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 [CA3167]
— 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 [CA3253]
— Failure Code [CA3254]
— Failure Code [CA3255]
— Failure Code [CA3256]
— Failure Code [CA3311]
— Failure Code [CA3312]
— Failure Code [CA3313]
— Failure Code [CA3314]
— Failure Code [CA3315]
— Failure Code [CA3316]
— Failure Code [CA3317]
— Failure Code [CA3318]
— Failure Code [CA3319]
— Failure Code [CA3321]
— Failure Code [CA3322]
— 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 [CA3725]
— Failure Code [CA3748]
— Failure Code [CA3751]
— Failure Code [CA3755]
— Failure Code [CA3866]
— Failure Code [CA3867]
— Failure Code [CA3868]
— Failure Code [CA3899]
— Failure Code [CA3911]
— Failure Code [CA3912]
— Failure Code [CA3932]
— Failure Code [CA3933]
— Failure Code [CA3934]
— Failure Code [CA3935]
— Failure Code [CA3936]
— Failure Code [CA4151]
— Failure Code [CA4152]
— Failure Code [CA4155]
— Failure Code [CA4156]
— Failure Code [CA4157]
— Failure Code [CA4158]
— Failure Code [CA4159]
— Failure Code [CA4161]
— Failure Code [CA4162]
— Failure Code [CA4163]
— 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 [CA4259]
— Failure Code [CA4261]
— Failure Code [CA4277]
— Failure Code [CA4281]
— Failure Code [CA4459]
— Failure Code [CA4461]
— Failure Code [CA4658]
— Failure Code [CA4731]
— Failure Code [CA4732]
— Failure Code [CA4739]
— Failure Code [CA4768]
— Failure Code [CA4769]
— Failure Code [CA4842]
— Failure Code [CA4952]
— Failure Code [CA5115]
— Failure Code [CA5179]
— Failure Code [CA5181]
— Failure Code [CA5383]
— Failure Code [D110KB]
— Failure Code [D19JKZ]
— Failure Code [D811MC]
— Failure Code [D862KA]
— Failure Code [D8ALKA]
— Failure Code [D8ALKB]
— Failure Code [D8AQKR]
— Failure Code [D8G1KT]
— Failure Code [D8G6KT]
— Failure Code [DA20MC]
— Failure Code [DA22KK]
— Failure Code [DA25KP]
— Failure Code [DA29KQ]
— Failure Code [DA2LKA]
— Failure Code [DA2LKB]
— Failure Code [DA2QKR]
— Failure Code [DA2RKR]
— Failure Code [DAF0MB]
— Failure Code [DAF0MC]
— Failure Code [DAF8KB]
— Failure Code [DAF9KQ]
— Failure Code [DAFGMC]
— Failure Code [DAFLKA]
— Failure Code [DAFLKB]
— Failure Code [DAFQKR]
— Failure Code [DAZ9KQ]
— Failure Code [DAZQKR]
— Failure Code [DB2QKR]
— Failure Code [DB2RKR]
— Failure Code [DBP0KM]
— Failure Code [DBP0KT]
— Failure Code [DBP5KB]
— Failure Code [DBP5KY]
— Failure Code [DBPQKR]
— Failure Code [DDNRKA] (Applicable Machine: 85001 to 86281)
— Failure Code [DDNRKA] (Applicable Machine: 86282 and up)
— Failure Code [DDNRKY] (Applicable Machine: 86282 and up)
— Failure Code [DDNRKY] (Applicable Machine: 86282 and up)
— Failure Code [DDNS00] (Applicable Machine: 85001 to 86281)
— Failure Code [DDNS00] (Applicable Machine: 86282 and up)
— Failure Code [DGH2KA]
— Failure Code [DGH2KB]
— Failure Code [DHA4KA]
— Failure Code [DHAAMA]
— Failure Code [DHACMA]
— Failure Code [DHPAMA]
— Failure Code [DHPBMA]
— 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 [DHSVMA]
— Failure Code [DHZAMA]
— Failure Code [DHZCL8]
— Failure Code [DKR0MA]
— Failure Code [DKR1MA]
— Failure Code [DKULKA] (Applicable Machine: 85001 to 86281)
— Failure Code [DKULKA] (Applicable Machine: 86282 and up)
— Failure Code [DKULKB] (Applicable Machine: 85001 to 86281)
— Failure Code [DKULKB] (Applicable Machine: 86282 and up)
— Failure Code [DKULKY] (Applicable Machine: 85001 to 86281)
— Failure Code [DKULKY] (Applicable Machine: 86282 and up)
— Failure Code [DLM3KA]
— Failure Code [DLM3KB]
— Failure Code [DLM3MB]
— Failure Code [DR10KA]
— Failure Code [DR12KA]
— Failure Code [DR20KA]
— Failure Code [DR21KX]
— Failure Code [DR30KA]
— Failure Code [DR31KX]
— Failure Code [DR40KA]
— Failure Code [DUMBKA]
— Failure Code [DUMBKB]
— Failure Code [DV20KB]
— Failure Code [DW43KA]
— Failure Code [DW43KB]
— Failure Code [DW43KY]
— Failure Code [DW45KA]
— Failure Code [DW45KB]
— Failure Code [DW45KY]
— Failure Code [DW4CKY] (Applicable Machine: 85001 to 86281)
— Failure Code [DW4CKY] (Applicable Machine: 86282 and up)
— Failure Code [DW7BKA]
— Failure Code [DW7BKB]
— Failure Code [DW7BKY]
— Failure Code [DW91KA]
— Failure Code [DW91KB]
— Failure Code [DW91KY]
— Failure Code [DWA2KA]
— Failure Code [DWA2KB]
— Failure Code [DWA2KY]
— Failure Code [DWK0KA]
— Failure Code [DWK0KB]
— Failure Code [DWK0KY]
— Failure Code [DWK2KA]
— Failure Code [DWK2KB]
— Failure Code [DWK2KY]
— Failure Code [DWK8KA]
— Failure Code [DWK8KB]
— Failure Code [DWK8KY]
— Failure Code [DWPUKA]
— Failure Code [DWPUKB]
— Failure Code [DWPUKY]
— Failure Code [DX16KA]
— Failure Code [DX16KB]
— Failure Code [DXA8KA]
— Failure Code [DXA8KB]
— Failure Code [DXA9KA]
— Failure Code [DXA9KB]
— Failure Code [DXE0KA]
— Failure Code [DXE0KB]
— Failure Code [DXE4KA]
— Failure Code [DXE4KB]
— Failure Code [DXE4KY]
— Failure Code [DXE5KA]
— Failure Code [DXE5KB]
— Failure Code [DXE6KA]
— Failure Code [DXE6KB]
— Failure Code [DXE7KA]
— Failure Code [DXE7KB]
— Failure Code [DXE7KY]
— Failure Code [DXE8KA]
— Failure Code [DXE8KB]
— Failure Code [DXE8KY]
— Failure Code [DXE9KA]
— Failure Code [DXE9KB]
— Failure Code [DXE9KY]
— Failure Code [DXEAKA]
— Failure Code [DXEAKB]
— Failure Code [DXEAKY]
— Failure Code [DXEKKA]
— Failure Code [DXEKKB]
— Failure Code [DXEKKY]
— Failure Code [DXELKA]
— Failure Code [DXELKB]
— Failure Code [DXELKY]
— 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 [F315KB]
— Failure Code [F315KY]
— 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]
– Troubleshooting of Electrical System (E-Mode)
— E-1 Engine Does Not Start (Engine Does Not Crank)
— E-2 Manual Preheating System Does Not Operate
— E-3 Automatic Preheating System Does Not Operate
— E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On
— E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
— E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow
— E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow
— E-8 Engine Coolant Temperature Monitor Comes On in White While Engine Runs
— E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs
— E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs
— E-11 Charge Level Monitor Comes On in Red While Engine is in Operation
— E-12 Fuel Level Monitor Comes On in Red While Engine Runs
— E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
— E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation
— E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation
— E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum
— E-17 Display of Fuel Gauge is Different from Actual Fuel Level
— E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
— E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature
— E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum
— E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature
— E-22 Some Areas of Machine Monitor Screen are Not Shown
— E-23 Function Switch Does Not Operate
— E-24 Automatic Warm-up System Does Not Work (in Cold Weather)
— E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out
— E-26 Auto-Decelerator is Not Operated or Canceled with Lever
— E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown
— E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
— E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change
— E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change
— E-31 Alarm Buzzer Cannot be Canceled
— E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position
— E-33 Service Mode Cannot be Selected
— E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move (Applicable Machine: 85001 to 86281)
— E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move (Applicable Machine: 86282 and up)
— E-35 All Work Equipment, Swing and Travel Do Not Lock (Applicable Machine: 85001 to 86281)
— E-35 All Work Equipment, Swing and Travel Do Not Lock (Applicable Machine: 86282 and up)
— E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing
— E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate
— E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor
— E-39 One-Touch Power Maximizing Function is Not Cancelled
— E-40 Alarm Does Not Sound During Travel
— E-41 Alarm Does Not Stop When Machine Stops
— E-42 Horn Does Not Sound
— E-43 Horn Does Not Stop
— E-44 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out
— E-45 When Wiper Switch is Operated, Windshield Wiper Does Not Operate
— E-46 Window Washer Does Not Operate When Window Washer Switch is Operated
— E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function
— E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function
— E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function
— E-50 “Arm IN” is Not Shown Correctly with Monitoring Function
— E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function
— E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function
— E-53 “Swing” is Not Shown Correctly with Monitoring Function
— E-54 “Travel” is Not Shown Correctly with Monitoring Function
— E-55 Service is Not Shown Correctly with Monitoring Function
— E-56 Attachment Hydraulic Circuit Cannot be Changed
— E-57 KOMTRAX System Does Not Operate Correctly
— E-58 Machine Push-up Function Cannot be Canceled (Applicable Machine: 85001 to 86281)
— E-58 Machine Push-up Function Cannot be Canceled (Applicable Machine: 86282 and up)
— E-59 Machine Push-Up Function Does Not Operate (Applicable Machine: 85001 to 86281)
— E-59 Machine Push-Up Function Does Not Operate (Applicable Machine: 86282 and up)
– Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
— Information Shown in Troubleshooting Table (H-Mode)
— System Chart of Hydraulic and Mechanical Systems
— Failure Mode and Cause Table
— H-1 All Work Equipment, Swing and Travel Do Not Work
— H-2 All Work Equipment, Swing and Travel Lack Speed and Power
— H-3 Fine Control Performance or Response is Unsatisfactory
— H-4 Unusual Noise is Heard from Around Hydraulic Pump
— H-5 Engine Speed Drops Largely or Engine Stops
— H-6 Speed or Power of Boom is Low
— H-7 Arm Speed or Power is Low
— H-8 Bucket Speed or Power is Low
— H-9 Work Equipment Does Not Move in Single Operation
— H-10 Hydraulic Drift of Boom is Large
— H-11 Hydraulic Drift of Arm is Large
— H-12 Hydraulic Drift of Bucket is Large
— H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves
— H-14 Time Lag of Work Equipment is Large
— H-15 One-Touch Power Maximizing Function Does Not Operate
— H-16 Machine Push-Up Function Does Not Operate
— H-17 Attachment Circuit Cannot be Changed
— H-18 Oil Flow in Attachment Circuit Cannot be Changed
— H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower
— H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely
— H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low
— H-22 Machine Does Not Travel Straight
— H-23 Machine is Not Steered Correctly or Steering Power is Low
— H-24 Travel Speed is Low
— H-25 One of Tracks Does Not Run
— H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast
— H-27 Upper Structure Does Not Swing to Right or Left
— H-28 Upper Structure Swings Only to Right or Left
— H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left
— H-30 Swing Acceleration or Swing Speed is Low in Only One Direction
— H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)
— H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)
— H-33 Shock is Large When Upper Structure Stops Swing Operation
— H-34 There is Large Unusual Noise When It Stops Swing Operation
— H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)
— H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)
— H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
— H-38 Unusual Noise is Heard from Around Fan
– Troubleshooting of Engine (S-Mode)
— Information Shown in Troubleshooting Table (S-Mode)
— S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position
— S-2 Engine Cranks but No Exhaust Smoke Comes Out
— S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
— S-4 Engine Startability is Unsatisfactory
— S-5 Engine Does Not Pick Up Smoothly
— S-6 Engine Stops During Operation
— S-7 Engine Runs Rough or is Not Stable
— S-8 Engine Lacks Power
— S-9 KDPF Becomes Clogged in a Short Time
— S-10 Engine Oil Consumption is Excessive
— S-11 Oil Becomes Dirty Quickly
— S-1 Fuel Consumption is Excessive
— S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level goes Down)
— S-14 Oil Pressure Drops
— S-15 Fuel Mixes Into Engine Oil
— S-16 Water Mixes Into Engine Oil (Milky)
— S-17 Coolant Temperature Increases Too High (Overheating)
— S-18 Unusual Noise is Heard
— S-19 Vibration is Excessive
— S-2 Air Cannot be Bled from Fuel Circuit
— S-21 Active Regeneration is Done Frequently
— S-22 Active Regeneration Continues Long
— S-23 White Smoke is Exhausted During Active Regeneration
— S-24 DEF Consumption is Excessive
— S-25 There is Unusual Smell (Irritating Odor)
— S-26 Foreign Materials Enter DEF (DEF Increases)
50 Disassembly and Assembly
– Table of Contents
– Precautions Before Work
– 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
— How to Remove Supply Pump Assembly
— How to Install Supply Pump Assembly
— Remove and Install Injector Assembly
— How to Remove Injector Assembly
— How to Install Injector Assembly
— Remove and Install Fuel Doser Assembly
— How to Remove Fuel Doser
— How to Install Fuel Doser
— 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 Alternator Belt
— How to Remove Alternator Belt
— How to Install Alternator Belt
— Remove and Install Radiator Assembly
— How to Remove Radiator Assembly
— How to Install Radiator Assembly
— Remove and Install Cooling Fan and Fan Motor Assembly
— How to Remove Cooling Fan and Fan Motor Assembly
— How to Install Cooling Fan and Fan Motor 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 Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205)
— How to Remove Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205)
— How to Install Engine and Main Pump Assembly (Applicable Machine: 85001 to 86205)
— Remove and Install Engine and Main Pump Assembly (Applicable Machine: 86206 and up)
— How to Remove Engine and Main Pump Assembly (Applicable Machine: 86206 and up)
— How to Install Engine and Main Pump Assembly (Applicable Machine: 86206 and up)
— 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 Engine Hood Assembly
— How to Remove Engine Hood Assembly
— How to Install Engine Hood 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 Filler Port Filter
— How to Remove DEF Tank Filler Port Filter
— How to Install DEF Tank Filler Port Filter
— Remove and Install KDPF Assembly (Applicable Machine: 85001 to 86205)
— How to Remove KDPF Assembly (Applicable Machine: 85001 to 86205)
— How to Install KDPF Assembly (Applicable Machine: 85001 to 86205)
— Remove and Install KDPF Assembly (Applicable Machine: 86206 and up)
— How to Remove KDPF Assembly (Applicable Machine: 86206 and up)
— How to Install KDPF Assembly (Applicable Machine: 86206 and up)
— Disassemble and Assemble of KDPF Assembly (Applicable Machine:85001 to 86205)
— How to Disassemble KDPF Assembly (Applicable Machine: 85001 to 86205)
— How to Assemble KDPF Assembly (Applicable Machine: 85001 to 86205)
— Disassemble and Assemble KDPF Assembly (Applicable Machine:86206 and up)
— How to Disassemble KDPF Assembly (Applicable Machine:86206 and up)
— How to Assemble KDPF Assembly (Applicable Machine: 86206 and up)
— Remove and Install SCR Assembly (Applicable Machine: 85001 to 86205)
— How to Remove SCR Assembly (Applicable Machine: 85001 to 86205)
— How to Install SCR Assembly (Applicable Machine: 85001 to 86205)
— Remove and Install SCR Assembly (Applicable Machine: 86206 and up)
— How to Remove SCR Assembly (Applicable Machine: 86206 and up)
— How to Install SCR Assembly (Applicable Machine: 86206 and up)
— Remove and Install KDPF and SCR Assembly (Applicable Machine: 85001 to 86205)
— How to Remove KDPF and SCR Assembly (Applicable Machine: 85001 to 86205)
— How to Install KDPF and SCR Assembly (Applicable Machine: 85001 to 86205)
— Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up)
— How to Remove KDPF and SCR Assembly (Applicable Machine: 86206 and up)
— How to Install KDPF and SCR Assembly (Applicable Machine: 86206 and up)
— Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205)
— How to Remove KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205)
— Install KDPF and SCR Assembly Bracket (Applicable Machine: 85001 to 86205)
— Remove and Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up)
— How to Remove KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up)
— Install KDPF and SCR Assembly Bracket (Applicable Machine: 86206 and up)
— 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 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 (Applicable Machine: 85001 to 86052)
— How to Install DEF Pump (Applicable Machine: 85001 to 86052)
— How to Remove DEF Pump (Applicable Machine: 86053 and up)
— How to Install DEF Pump (Applicable Machine: 86053 and up)
— Remove and Install DEF Hose
— How to Remove DEF Hose (Applicable Machine: 85001 to 86052)
— How to Install DEF Hose (Applicable Machine: 85001 to 86052)
— How to Remove DEF Hose (Applicable Machine: 86053 and up)
— How to Install DEF Hose (Applicable Machine: 86053 and up)
— 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 Final Drive Assembly
— How to Disassemble Final Drive Assembly
— How to Assemble Final Drive Assembly
— 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
— Disassemble and Assemble Carrier Roller Assembly
— How to Disassemble Carrier Roller Assembly
— How to Assemble Carrier 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 Replace Pressure Compensation Valve Seal Ring
— How to Assemble Control Valve Assembly
— Remove and Install ATT Bypass Solenoid
— How to Remove ATT Bypass Solenoid
— How to Install ATT Bypass Solenoid
— 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 Work Equipment Assembly
— How to Remove Work Equipment Assembly
— How to Install Work Equipment Assembly
— Remove and Install Boom Anti-drop Valve Assembly
— How to Remove Boom Anti-drop Valve Assembly
— How to Install Boom Anti-drop Valve Assembly
— Remove and Install Arm Anti-Drop Valve Assembly
— How to Remove Arm Anti-Drop Valve Assembly
— How to Install Arm Anti-Drop Valve Assembly
— Disassemble and Assemble Anti-Drop Valve Assembly
— How to Disassemble Anti-Drop Valve Assembly
— How to Assemble Anti-Drop Valve 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 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 Machine Monitor Assembly
— How to Remove Machine Monitor Assembly
— How to Install Machine Monitor Assembly
— Remove and Install KomVision Controller Assembly
— How to Remove KomVision Controller Assembly
— How to Install KomVision Controller Assembly
— Remove and Install Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205
— How to Remove Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205)
— How to Install Pump Swash Plate Sensor (Applicable Machine: 85001 to 86205)
— Remove and Install Pump Swash Plate Sensor (Applicable Machine: 86206 and up)
— How to Remove Pump Swash Plate Sensor (Applicable Machine: 86206 and up)
— How to Install Pump Swash Plate Sensor (Applicable Machine: 86206 and up)
— 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 (Applicable Machine:85001 to 86205)
— Remove SCR Temperature Sensor (Applicable Machine:85001 to 86205)
— Install SCR Temperature Sensor (Applicable Machine:85001 to 86205)
— Remove and Install SCR Temperature Sensor (Applicable Machine:86206 and up)
— How to Remove SCR Temperature Sensor (Applicable Machine:86206 and up)
— How to Install SCR Temperature Sensor (Applicable Machine:86206 and up)
— Remove and Install KomVision Camera
— How to Remove KomVision Camera
— How to Install KomVision Camera
— 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
– Engine and Cooling System
— Maintenance Standard for Engine Mount
— Maintenance Standard for Cooling System
— Maintenance Standard for Cooling Fan Pump
— Maintenance Standard for Servo Valve
— Maintenance Standard for Cooling Fan Motor
– Power Train
— Maintenance Standard for Swing Circle
— Maintenance Standard for Swing Machinery
— Maintenance Standard for Final Drive
— Maintenance Standard for Sprocket
— Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing
– 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
– Hydraulic System
— Maintenance Standard for Main Pump
— Maintenance Standard for Swing Motor
— Maintenance Standard for Travel Motor
— Maintenance Standard for Control Valve
— Maintenance Standard for Boom Anti-Drop Valve
— Maintenance Standard for Arm Anti-Drop Valve
— Maintenance Standard for Work Equipment and Swing 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 Attachment Circuit Selector Valve
— 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
80 Appendix
– Table of Contents
– Precautions Before Work
– 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
— Receiver Drier
— Structure of Receiver Dryer
— Specifications of Receiver Dryer
— Function of Receiver Dryer
— 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]
– A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
– A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
– A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
– A-4 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
90 Circuit Diagrams
– Table of Contents
– Hydraulic Circuit Diagram
— Symbols Used in Hydraulic Circuit Diagram
— Hydraulic Circuit Diagram (1/2)
— Hydraulic Circuit Diagram (2/2)
– Electrical Circuit Diagram
— Symbols Used in Electric Circuit Diagram
— Electrical Circuit Diagram (1/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (2/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (3/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (4/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (5/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (6/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (7/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (8/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (9/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (10/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (11/11) (Applicable Machine: 85001 to 86281)
— Electrical Circuit Diagram (1/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (2/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (3/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (4/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (5/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (6/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (7/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (8/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (9/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (10/11) (Applicable Machine: 86282 and up)
— Electrical Circuit Diagram (11/11) (Applicable Machine: 86282 and up)
Index