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KOMATSU PC200-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06867-07 – PDF DOWNLOAD
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KOMATSU PC200-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06867-07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC200-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06867-07 – PDF DOWNLOAD
Language : English
Pages : 2248
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC200-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06867-07 – PDF DOWNLOAD
00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 16 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 21 HOW TO READ THE SHOP MANUAL..................................................................................................... 21 SAFETY NOTICE FOR OPERATION..................................................................................................... 23 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 31 ACTIONS IF FIRE OCCURS.......................................................................................................... 32 PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS................................................................................. 33 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 34 PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS............................................................................. 37 PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT................................................................................ 44 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 46 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 47 PRACTICAL USE OF KOMTRAX........................................................................................................ 48 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 49 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 49 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 50 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 51 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 53 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 57 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 60 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 61 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 63 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 64 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 68 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 71 CONVERSION TABLE................................................................................................................ 78 01 SPECIFICATION........................................................................................................................ 83 CONTENTS............................................................................................................................ 84 ABBREVIATION LIST................................................................................................................... 85 SPECIFICATIONS...................................................................................................................... 90 SPECIFICATION DRAWING........................................................................................................... 90 SPECIFICATION DRAWING: PC200-10M0........................................................................................... 90 WORKING RANGE DRAWINGS.......................................................................................................... 92 WORKING RANGE DRAWINGS: PC200-10M0.......................................................................................... 92 SPECIFICATIONS.................................................................................................................. 94 SPECIFICATION: PC200-10M0................................................................................................... 94 WEIGHT TABLE.................................................................................................................... 97 WEIGHT TABLE: PC200-10M0.................................................................................................... 97 FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE......................................................................... 99 10 STRUCTURE AND FUNCTION............................................................................................................... 101 CONTENTS............................................................................................................................ 102 ABBREVIATION LIST................................................................................................................... 105 BOOT-UP SYSTEM...................................................................................................................... 110 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 110 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 111 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 111 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 111 OPERATION OF SYSTEM OPERATING LAMP.......................................................................................... 111 BATTERY DISCONNECT SWITCH....................................................................................................... 112 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 112 OPERATION OF BATTERY DISCONNECT SWITCH...................................................................................... 112 ENGINE SYSTEM....................................................................................................................... 113 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 113 ENGINE CONTROL SYSTEM........................................................................................................... 114 ENGINE CONTROL SYSTEM DRAWING............................................................................................... 114 OPERATION OF ENGINE CONTROL SYSTEM.......................................................................................... 114 AUTO-DECELERATION SYSTEM........................................................................................................ 116 AUTO-DECELERATION SYSTEM DRAWING............................................................................................ 116 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 116 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 117 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 118 ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING..................................................................................... 118 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 119 OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................ 119 OVERHEAT PREVENTION SYSTEM...................................................................................................... 120 OVERHEAT PREVENTION SYSTEM DRAWING.......................................................................................... 120 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 121 OPERATION OF OVERHEAT PREVENTION SYSTEM..................................................................................... 121 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 123 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 123 COOLING SYSTEM...................................................................................................................... 124 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 124 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 125 CONTROL SYSTEM...................................................................................................................... 126 LAYOUT DRAWING OF CONTROL SYSTEM PARTS.......................................................................................... 126 MACHINE MONITOR SYSTEM.......................................................................................................... 128 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 128 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 128 KOMTRAX SYSTEM.................................................................................................................. 130 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 130 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 130 CONTROL SYSTEM.................................................................................................................. 131 MACHINE MONITOR............................................................................................................. 131 GATEWAY FUNCTION CONTROLLER................................................................................................. 142 PUMP CONTROLLER............................................................................................................. 145 RESISTOR FOR PC-EPC VALVE................................................................................................... 149 CAN TERMINATING RESISTOR.................................................................................................... 149 ENGINE CONTROLLER........................................................................................................... 150 FUEL CONTROL DIAL........................................................................................................... 154 HYDRAULIC SYSTEM.................................................................................................................... 155 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 155 CLSS............................................................................................................................ 158 CLSS SYSTEM DIAGRAM......................................................................................................... 158 FUNCTION OF CLSS............................................................................................................ 159 PRESSURE COMPENSATION CONTROL............................................................................................... 176 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 177 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 177 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 178 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 182 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 182 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 183 HYDRAULIC SYSTEM................................................................................................................ 185 HYDRAULIC TANK.............................................................................................................. 185 MAIN PUMP................................................................................................................... 187 CONTROL VALVE............................................................................................................... 207 WORK EQUIPMENT SYSTEM............................................................................................................... 251 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 251 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 255 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 255 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 256 PPC LOCK SYSTEM................................................................................................................. 257 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 257 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 258 ATTACHMENT OIL FLOW ADJUSTER SYSTEM............................................................................................. 259 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................. 259 FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM............................................................................. 260 WORK EQUIPMENT SYSTEM........................................................................................................... 261 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 261 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 265 2ND-LINE ATTACHMENT PPC VALVE............................................................................................... 269 SOLENOID VALVE.............................................................................................................. 273 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)....................................................................... 275 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)........................................................................ 277 PILOT CIRCUIT ACCUMULATOR................................................................................................... 280 ATTACHMENT CIRCUIT ACCUMULATOR.............................................................................................. 280 SWING SYSTEM........................................................................................................................ 283 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 283 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 285 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 285 SWING SYSTEM.................................................................................................................... 289 SWING MOTOR................................................................................................................. 289 SWING MACHINERY............................................................................................................. 295 SWING CIRCLE................................................................................................................ 298 TRAVEL SYSTEM....................................................................................................................... 299 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 299 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 301 FUNCTION OF TRAVEL CONTROL SYSTEM............................................................................................... 302 TRAVEL SYSTEM................................................................................................................... 303 TRAVEL MOTOR................................................................................................................ 303 FINAL DRIVE................................................................................................................. 314 TRAVEL PPC VALVE............................................................................................................ 315 CENTER SWIVEL JOINT......................................................................................................... 320 FUNCTION OF SWING CIRCLE............................................................................................................ 322 UNDERCARRIAGE AND FRAME............................................................................................................. 323 LAYOUT DRAWING OF UNDERCARRIAG.................................................................................................. 323 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 323 WORK EQUIPMENT...................................................................................................................... 325 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 325 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 326 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 326 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 327 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 327 CAB RELATED PARTS................................................................................................................... 328 ROPS CAB........................................................................................................................ 328 STRUCTURE OF ROPS CAB....................................................................................................... 328 FUNCTION OF ROPS CAB........................................................................................................ 328 CAB MOUNT....................................................................................................................... 329 STRUCTURE OF CAB MOUNT...................................................................................................... 329 FUNCTION OF CAB MOUNT....................................................................................................... 330 CAB TIPPING STOPPER............................................................................................................. 331 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 331 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 331 20 STANDARD VALUE TABLE................................................................................................................. 333 CONTENTS............................................................................................................................ 334 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 335 STANDARD VALUE TABLE FOR ENGINE: PC200-10M0..................................................................................... 335 STANDARD VALUE TABLE FOR MACHINE: PC200-10M0.................................................................................... 339 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE........................................................................... 352 30 TESTING AND ADJUSTING................................................................................................................ 355 CONTENTS............................................................................................................................ 356 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 359 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 359 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 364 ENGINE AND COOLING SYSTEM........................................................................................................... 366 TEST ENGINE SPEED............................................................................................................... 366 TEST ENGINE HIGH IDLE SPEED................................................................................................. 366 Test engine low idle speed.................................................................................................. 366 TEST ENGINE SPEED AT 2 PUMPS RELIEF......................................................................................... 366 Test engine speed at 2 pumps relief and one-touch power maximizing.......................................................... 367 TEST ENGINE SPEED WITH AUTO-DECELERATION.................................................................................... 367 Test boost pressure............................................................................................................. 369 TEST BOOST PRESSURE ON MACHINE MONITOR...................................................................................... 369 TEST BOOST PRESSURE BY TESTING TOOL......................................................................................... 370 TEST EXHAUST GAS COLOR.......................................................................................................... 372 Test exhaust gas color by handy smoke checker............................................................................... 372 TEST EXHAUST GAS COLOR BY SMOKE METER....................................................................................... 373 Test and adjust valve clearance................................................................................................. 375 TEST VALVE CLEARANCE........................................................................................................ 375 Adjust valve clearance...................................................................................................... 376 TEST COMPRESSION PRESSURE....................................................................................................... 378 TEST COMPRESSION PRESSURE................................................................................................... 378 TEST BLOWBY PRESSURE............................................................................................................ 381 TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT))......................................... 381 Test blowby pressure (machine without blowby pressure sensor)............................................................... 382 TEST ENGINE OIL PRESSURE........................................................................................................ 384 TEST ENGINE OIL PRESSURE.................................................................................................... 384 Test fuel pressure.............................................................................................................. 386 TEST FUEL PRESSURE.......................................................................................................... 387 TEST FUEL DISCHARGE, RETURN AND LEAKAGE......................................................................................... 392 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE....................................................................... 393 BLEED AIR FROM FUEL SYSTEM...................................................................................................... 397 Bleed air from fuel system.................................................................................................. 397 Test fuel system for leakage.................................................................................................... 399 Test fuel circuit for leakage............................................................................................... 399 CYLINDER CUT-OUT MODE OPERATION................................................................................................. 401 NO-INJECTION CRANKING OPERATION................................................................................................. 402 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 403 CHECK AIR CONDITIONER COMPRESSOR BELT....................................................................................... 403 ADJUST AIR CONDITIONER COMPRESSOR BELT...................................................................................... 403 POWER TRAIN......................................................................................................................... 405 Test swing circle bearing clearance............................................................................................. 405 Test swing circle bearing clearance......................................................................................... 405 UNDERCARRIAGE AND FRAME............................................................................................................. 406 Test and adjust track shoe tension.............................................................................................. 406 Test track shoe tension..................................................................................................... 406 Adjust track shoe tension................................................................................................... 406 HYDRAULIC SYSTEM.................................................................................................................... 408 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 408 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.............................................................................. 408 Release remaining pressure in hydraulic cylinder circuit.................................................................... 408 Release remaining pressure for machines without anti-drop valve............................................................. 408 Release remaining pressure for machines with boom anti-drop valve........................................................... 408 Release remaining pressure from swing motor circuit......................................................................... 410 RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT........................................................................ 410 Test and adjust oil pressure in work equipment, swing, and travel circuits...................................................... 411 Test oil pressure in work equipment, swing, and travel circuits............................................................. 411 Adjust oil pressure in work equipment, swing, and travel circuits........................................................... 418 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 420 Test oil pressure of control circuit........................................................................................ 420 Test and adjust oil pressure in pump PC control circuit......................................................................... 422 Test PC valve outlet pressure (servo piston inlet pressure)................................................................. 422 TEST PC-EPC VALVE OUTLET PRESSURE........................................................................................... 423 Adjust oil pressure in pump PC control circuit.............................................................................. 424 Test and adjust oil pressure in pump LS control circuit......................................................................... 426 Test LS differential pressure with machine monitor.......................................................................... 426 Test LS differential pressure by testing tool............................................................................... 428 Test LS valve outlet pressure (servo piston inlet pressure)................................................................. 429 Test LS-EPC valve outlet pressure........................................................................................... 431 Adjust LS valve............................................................................................................. 432 Test outlet pressure of solenoid valve.......................................................................................... 433 Test outlet pressure of solenoid valve...................................................................................... 433 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 435 Test PPC valve outlet pressure.................................................................................................. 437 Test outlet pressure of PPC valve with machine monitor...................................................................... 437 TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL........................................................................... 438 Adjust play of work equipment and swing PPC valve............................................................................... 441 Adjust play of work equipment and swing PPC valve........................................................................... 441 Test parts causing hydraulic drift in work equipment............................................................................ 442 Test parts causing hydraulic drift of boom cylinder and bucket cylinder..................................................... 442 Test parts causing hydraulic drift of arm cylinder.......................................................................... 442 Test parts causing hydraulic drift of boom hydraulic drift prevention valve................................................. 443 Test parts causing hydraulic drift of PPC valve............................................................................. 443 Test oil leakage................................................................................................................ 444 TEST OIL LEAKAGE FROM BOOM CYLINDER......................................................................................... 444 TEST OIL LEAKAGE FROM ARM CYLINDER.......................................................................................... 445 TEST OIL LEAKAGE FROM BUCKET CYLINDER....................................................................................... 446 Test oil leakage from swing motor........................................................................................... 446 Test oil leakage from travel motor.......................................................................................... 447 Bleed air from hydraulic system................................................................................................. 449 Bleed air from main pump.................................................................................................... 450 BLEED AIR FROM CYLINDER..................................................................................................... 451 BLEED AIR FROM SWING MOTOR.................................................................................................. 452 BLEED AIR FROM TRAVEL MOTOR................................................................................................. 452 CAB RELATED PARTS................................................................................................................... 454 Test cab tipping stopper........................................................................................................ 454 Test cab tipping stopper.................................................................................................... 454 ADJUST MIRRORS.................................................................................................................. 455 ADJUST MACHINE LEFT FRONT MIRROR (A)........................................................................................ 455 Adjust regular position of machine left front mirror (A).................................................................... 456 ADJUST MACHINE RIGHT FRONT MIRROR (B)....................................................................................... 457 ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)................................................................... 457 ADJUST MACHINE RIGHT SIDE MIRROR (C)........................................................................................ 458 ELECTRICAL SYSTEM................................................................................................................... 460 SET AND OPERATE MACHINE MONITOR................................................................................................. 460 OPERATOR MODE............................................................................................................... 464 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 464 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 464 CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY).............................................................................. 465 CHECK FUNCTION OF SERVICE METER............................................................................................. 465 SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD........................................................................ 465 SERVICE MODE................................................................................................................ 468 OPERATE SERVICE MODE........................................................................................................ 468 Check pre-defined monitoring information.................................................................................... 469 CHECK MONITORING INFORMATION................................................................................................ 474 ABNORMALITY RECORD MENU..................................................................................................... 481 CHECK MAINTENANCE RECORD.................................................................................................... 484 MAINTENANCE MODE SETTING.................................................................................................... 486 Phone number entry setting.................................................................................................. 490 DEFAULT SETTING MENU........................................................................................................ 491 TESTING MENU................................................................................................................ 500 ADJUSTMENT MENU............................................................................................................. 503 NO-INJECTION CRANKING OPERATION............................................................................................. 515 KOMTRAX SETTINGS MENU....................................................................................................... 518 Display service message..................................................................................................... 520 START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).............................................................. 522 STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)......................................................... 528 Adjust rearview camera angle.................................................................................................... 530 ADJUST REARVIEW CAMERA ANGLE................................................................................................ 530 ENGINE CONTROLLER VOLTAGE CIRCUIT............................................................................................... 532 TEST DIODES..................................................................................................................... 533 TEST DIODES BY DIGITAL TESTER............................................................................................... 533 TEST DIODES BY ANALOG TESTER................................................................................................ 533 Pm-CLINIC........................................................................................................................... 534 PM CLINIC SERVICE............................................................................................................... 534 PM CLINIC CHECK SHEET: PC200-10M0........................................................................................... 537 40 TROUBLESHOOTING...................................................................................................................... 545 CONTENTS............................................................................................................................ 546 RELATED INFORMATION FOR TROUBLESHOOTING............................................................................................. 553 PRECAUTIONS FOR TROUBLESHOOTING................................................................................................. 553 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 554 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 556 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 558 WALK-AROUND CHECK........................................................................................................... 558 TEST ENGINE RELATED PARTS................................................................................................... 559 TEST WORK EQUIPMENT AND UNDERCARRIAGE....................................................................................... 561 CHECK ELECTRIC EQUIPMENT.................................................................................................... 562 CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER...................................................................................... 567 CONNECT ADAPTER TO TROUBLESHOOT MONITOR..................................................................................... 567 CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER............................................................................. 569 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL............................................................................ 573 CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER........................................................................... 575 CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR............................................................... 576 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH.............................................................................. 578 DISCONNECT AND CONNECT DEUTSCH CONNECTOR.................................................................................... 578 DISCONNECT AND CONNECT BOSCH CONNECTOR...................................................................................... 578 DISCONNECT AND CONNECT AMP CONNECTOR........................................................................................ 579 DISCONNECT AND CONNECT SUMITOMO CONNECTOR................................................................................... 580 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL.............................................................................. 581 DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR............................................................... 581 DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR..................................................................................... 582 DISCONNECT AND CONNECT FRAMATOME CONNECTOR.................................................................................. 582 DISCONNECT AND CONNECT TYCO CONNECTOR....................................................................................... 583 DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE......................................................................... 584 PROCEDURE FOR TROUBLESHOOTING................................................................................................... 585 INFORMATION DESCRIBED IN TROUBLESHOOTING........................................................................................ 586 DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS........................................................ 589 CONNECTOR LIST AND LAYOUT....................................................................................................... 592 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 604 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 646 FUSE LOCATION AND CONNECTION TABLE.............................................................................................. 652 DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING............................................................... 654 FAILURE CODES TABLE............................................................................................................. 656 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................... 664 FAILURE CODE [602KNX]........................................................................................................... 664 FAILURE CODE [6AZ0ZG]........................................................................................................... 667 FAILURE CODE [879AKA]........................................................................................................... 671 FAILURE CODE [879AKB]........................................................................................................... 673 FAILURE CODE [879BKA]........................................................................................................... 675 FAILURE CODE [879BKB]........................................................................................................... 678 FAILURE CODE [879CKA]........................................................................................................... 681 FAILURE CODE [879CKB]........................................................................................................... 683 FAILURE CODE [879DKZ]........................................................................................................... 685 FAILURE CODE [879EMC]........................................................................................................... 688 FAILURE CODE [879FMC]........................................................................................................... 690 FAILURE CODE [879GKX]........................................................................................................... 692 FAILURE CODE [989L00]........................................................................................................... 695 FAILURE CODE [989M00]........................................................................................................... 697 FAILURE CODE [989N00]........................................................................................................... 699 FAILURE CODE [A900FR]........................................................................................................... 700 FAILURE CODE [A900N6]........................................................................................................... 701 FAILURE CODE [A900NY]........................................................................................................... 702 FAILURE CODE [AA10NX]........................................................................................................... 703 FAILURE CODE [AB00KE]........................................................................................................... 706 FAILURE CODE [B@BAZG]........................................................................................................... 710 FAILURE CODE [B@BAZK]........................................................................................................... 711 FAILURE CODE [B@BCZK]........................................................................................................... 714 FAILURE CODE [B@BCNS]........................................................................................................... 716 FAILURE CODE [B@BCQA]........................................................................................................... 717 FAILURE CODE [B@HANS]........................................................................................................... 719 FAILURE CODE [CA111]............................................................................................................ 722 FAILURE CODE [CA115]............................................................................................................ 723 FAILURE CODE [CA122]............................................................................................................ 724 FAILURE CODE [CA123]............................................................................................................ 726 FAILURE CODE [CA131]............................................................................................................ 728 FAILURE CODE [CA132]............................................................................................................ 730 FAILURE CODE [CA135]............................................................................................................ 732 FAILURE CODE [CA141]............................................................................................................ 735 FAILURE CODE [CA144]............................................................................................................ 738 FAILURE CODE [CA145]............................................................................................................ 740 FAILURE CODE [CA153]............................................................................................................ 742 FAILURE CODE [CA154]............................................................................................................ 744 FAILURE CODE [CA155]............................................................................................................ 746 FAILURE CODE [CA187]............................................................................................................ 747 FAILURE CODE [CA221]............................................................................................................ 749 FAILURE CODE [CA222]............................................................................................................ 751 FAILURE CODE [CA227]............................................................................................................ 753 FAILURE CODE [CA234]............................................................................................................ 754 FAILURE CODE [CA238]............................................................................................................ 755 FAILURE CODE [CA271]............................................................................................................ 757 FAILURE CODE [CA272]............................................................................................................ 759 FAILURE CODE [CA322]............................................................................................................ 761 FAILURE CODE [CA324]............................................................................................................ 763 FAILURE CODE [CA331]............................................................................................................ 765 FAILURE CODE [CA332]............................................................................................................ 767 FAILURE CODE [CA342]............................................................................................................ 769 FAILURE CODE [CA351]............................................................................................................ 770 FAILURE CODE [CA352]............................................................................................................ 771 FAILURE CODE [CA386]............................................................................................................ 773 FAILURE CODE [CA428]............................................................................................................ 774 FAILURE CODE [CA429]............................................................................................................ 776 FAILURE CODE [CA435]............................................................................................................ 778 FAILURE CODE [CA441]............................................................................................................ 780 FAILURE CODE [CA442]............................................................................................................ 782 FAILURE CODE [CA449]............................................................................................................ 783 FAILURE CODE [CA451]............................................................................................................ 784 FAILURE CODE [CA452]............................................................................................................ 786 FAILURE CODE [CA488]............................................................................................................ 788 FAILURE CODE [CA553]............................................................................................................ 789 FAILURE CODE [CA559]............................................................................................................ 790 FAILURE CODE [CA689]............................................................................................................ 792 FAILURE CODE [CA731]............................................................................................................ 794 FAILURE CODE [CA757]............................................................................................................ 796 FAILURE CODE [CA778]............................................................................................................ 797 FAILURE CODE [CA2185]........................................................................................................... 802 FAILURE CODE [CA2186]........................................................................................................... 804 FAILURE CODE [CA2249]........................................................................................................... 806 FAILURE CODE [CA2311]........................................................................................................... 807 FAILURE CODE [CA2555]........................................................................................................... 808 FAILURE CODE [CA2556]........................................................................................................... 811 FAILURE CODE [D110KB]........................................................................................................... 813 FAILURE CODE [D19JKZ]........................................................................................................... 817 FAILURE CODE [D811MC]........................................................................................................... 821 FAILURE CODE [D862KA]........................................................................................................... 822 FAILURE CODE [D8ALKA]........................................................................................................... 825 FAILURE CODE [D8ALKB]........................................................................................................... 829 FAILURE CODE [D8AQKR]........................................................................................................... 832 FAILURE CODE [D8ARKR]........................................................................................................... 842 FAILURE CODE [D8G1KT]........................................................................................................... 848 FAILURE CODE [D8G6KT]........................................................................................................... 849 FAILURE CODE [DA20MC]........................................................................................................... 850 FAILURE CODE [DA22KK]........................................................................................................... 851 FAILURE CODE [DA25KP]........................................................................................................... 856 FAILURE CODE [DA26KP]........................................................................................................... 860 FAILURE CODE [DA29KQ]........................................................................................................... 866 FAILURE CODE [DA2LKA]........................................................................................................... 871 FAILURE CODE [DA2LKB]........................................................................................................... 875 FAILURE CODE [DA2QKR]........................................................................................................... 878 FAILURE CODE [DA2RKR]........................................................................................................... 889 FAILURE CODE [DAF0MB]........................................................................................................... 898 FAILURE CODE [DAF0MC]........................................................................................................... 899 FAILURE CODE [DAF8KB]........................................................................................................... 900 FAILURE CODE [DAF9KQ]........................................................................................................... 902 FAILURE CODE [DAFGMC]........................................................................................................... 904 FAILURE CODE [DAFLKA]........................................................................................................... 906 FAILURE CODE [DAFLKB]........................................................................................................... 910 FAILURE CODE [DAFQKR]........................................................................................................... 913 FAILURE CODE [DAZ9KQ]........................................................................................................... 923 FAILURE CODE [DAZQKR]........................................................................................................... 925 FAILURE CODE [DB2QKR]........................................................................................................... 934 FAILURE CODE [DDPAKA]........................................................................................................... 944 FAILURE CODE [DGH2KA]........................................................................................................... 947 FAILURE CODE [DGH2KB]........................................................................................................... 950 FAILURE CODE [DHA4KA]........................................................................................................... 953 FAILURE CODE [DHE5MA]........................................................................................................... 956 FAILURE CODE [DHPAMA]........................................................................................................... 960 FAILURE CODE [DHPBMA]........................................................................................................... 964 FAILURE CODE [DHS3MA]........................................................................................................... 968 FAILURE CODE [DHS4MA]........................................................................................................... 972 FAILURE CODE [DHS8MA]........................................................................................................... 976 FAILURE CODE [DHS9MA]........................................................................................................... 980 FAILURE CODE [DHSAMA]........................................................................................................... 984 FAILURE CODE [DHSBMA]........................................................................................................... 988 FAILURE CODE [DHSCMA]........................................................................................................... 992 FAILURE CODE [DHSDMA]........................................................................................................... 996 FAILURE CODE [DHSFMA]...........................................................................................................1000 FAILURE CODE [DHSGMA]...........................................................................................................1004 FAILURE CODE [DHSHMA]...........................................................................................................1008 FAILURE CODE [DHSJMA]...........................................................................................................1012 FAILURE CODE [DJG1KX]...........................................................................................................1016 FAILURE CODE [DKR2MA]...........................................................................................................1019 FAILURE CODE [DKR2NX]...........................................................................................................1023 FAILURE CODE [DR31KX]...........................................................................................................1025 FAILURE CODE [DV20KB]...........................................................................................................1026 FAILURE CODE [DW43KA]...........................................................................................................1029 FAILURE CODE [DW43KB]...........................................................................................................1032 FAILURE CODE [DW43KY]...........................................................................................................1035 FAILURE CODE [DW45KA]...........................................................................................................1037 FAILURE CODE [DW45KB]...........................................................................................................1041 FAILURE CODE [DW45KY]...........................................................................................................1045 FAILURE CODE [DW91KA]...........................................................................................................1048 FAILURE CODE [DW91KB]...........................................................................................................1050 FAILURE CODE [DW91KY]...........................................................................................................1053 FAILURE CODE [DWA2KA]...........................................................................................................1055 FAILURE CODE [DWA2KB]...........................................................................................................1057 FAILURE CODE [DWA2KY]...........................................................................................................1060 FAILURE CODE [DWK0KA]...........................................................................................................1062 FAILURE CODE [DWK0KB]...........................................................................................................1064 FAILURE CODE [DWK0KY]...........................................................................................................1067 FAILURE CODE [DWK2KA]...........................................................................................................1069 FAILURE CODE [DWK2KB]...........................................................................................................1071 FAILURE CODE [DWK2KY]...........................................................................................................1074 FAILURE CODE [DWK8KA]...........................................................................................................1076 FAILURE CODE [DWK8KB]...........................................................................................................1078 FAILURE CODE [DWK8KY]...........................................................................................................1081 FAILURE CODE [DXA8KA]...........................................................................................................1083 FAILURE CODE [DXA8KB]...........................................................................................................1086 FAILURE CODE [DXA9KA]...........................................................................................................1090 FAILURE CODE [DXA9KB]...........................................................................................................1093 FAILURE CODE [DXE0KA]...........................................................................................................1097 FAILURE CODE [DXE0KB]...........................................................................................................1100 FAILURE CODE [DXE4KA]...........................................................................................................1103 FAILURE CODE [DXE4KB]...........................................................................................................1106 FAILURE CODE [DXE4KY]...........................................................................................................1109 FAILURE CODE [DXE5KA]...........................................................................................................1111 FAILURE CODE [DXE5KB]...........................................................................................................1114 FAILURE CODE [DXE6KA]...........................................................................................................1117 FAILURE CODE [DXE6KB]...........................................................................................................1120 FAILURE CODE [DY20KA]...........................................................................................................1123 FAILURE CODE [DY20MA]...........................................................................................................1127 FAILURE CODE [DY2CKB]...........................................................................................................1131 FAILURE CODE [DY2DKB]...........................................................................................................1136 FAILURE CODE [DY2EKB]...........................................................................................................1139 FAILURE CODE [F313KA]...........................................................................................................1142 FAILURE CODE [F313KB]...........................................................................................................1144 FAILURE CODE [F318KB]...........................................................................................................1147 FAILURE CODE [F318KY]...........................................................................................................1150 FAILURE CODE [F@BBZL]...........................................................................................................1152 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1155 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...................................................................................1155 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................................................1165 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK.......................................................................................1169 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP..........................................................1173 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.................................................1178 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW..........1183 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW....1185 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION.......................................................1187 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION........................................................1189 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION....................................................1191 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION..............................................................1193 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION................................................................1197 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...........................................................1198 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION................................................1199 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.......................................................1201 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.................................................1202 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM................................................................................1204 FUEL GAUGE INDICATES INCORRECT LEVEL............................................................................................1207 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM.................................................................1209 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE.......................................................................1210 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM...........................................................1212 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE.................................................................1215 MACHINE MONITOR SHOWS INCORRECT MODEL...........................................................................................1217 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED..........................................................................1218 FUNCTION SWITCH DOES NOT OPERATE................................................................................................1219 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER).....................................................................1220 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED................................1222 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION..................................................1223 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED....................................................1226 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED.....................................................1227 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED......................................................1228 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED......................................................................1229 ALARM BUZZER DOES NOT STOP......................................................................................................1231 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION.........................................................1232 MACHINE DOES NOT CHANGE TO SERVICE MODE.........................................................................................1233 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE............................................................................1234 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK...............................................................................1238 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED.....................................................1240 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON...................................................................1244 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY.......................................1247 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED.............................................................................1251 TRAVEL ALARM DOES NOT SOUND.....................................................................................................1253 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS...................................................................................1256 HORN DOES NOT SOUND.............................................................................................................1258 HORN DOES NOT STOP..............................................................................................................1262 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED........................................................1264 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED............................................................................1265 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED............................................................1268 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.......................................................................1271 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.......................................................................1272 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.....................................................................1273 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION...........................................................................1274 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.................................................................1275 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.................................................................1276 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION............................................................................1277 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION...........................................................................1278 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION..................................................................1279 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................1282 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY........................................................................................1284 QUICK COUPLER DOES NOT WORK.....................................................................................................1286 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1291 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE).........................................................................1291 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK...............................................................................1292 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER......................................................................1294 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR....................................................................................1307 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...............................................................................1312 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS......................................................................................1314 BOOM SPEED OR POWER IS LOW......................................................................................................1323 Arm speed or power is low.......................................................................................................1335 BUCKET SPEED OR POWER IS LOW....................................................................................................1346 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION................................................................................1356 HYDRAULIC DRIFT OF BOOM IS LARGE................................................................................................1360 HYDRAULIC DRIFT OF ARM IS LARGE.................................................................................................1362 HYDRAULIC DRIFT OF BUCKET IS LARGE..............................................................................................1366 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES................................................1369 TIME LAG OF WORK EQUIPMENT IS LARGE.............................................................................................1371 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE............................................................................1378 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................1381 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED................................................................................1383 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER...............................................1385 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY...........................................................1387 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW...........................................................1388 MACHINE DOES NOT TRAVEL STRAIGHT................................................................................................1389 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW............................................................................1400 TRAVEL SPEED IS SLOW............................................................................................................1415 ONE OF TRACKS DOES NOT RUN......................................................................................................1426 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST...............................................................1435 MACHINE DOES NOT SWING TO RIGHT OR LEFT.........................................................................................1438 SWINGS ONLY IN ONE DIRECTION....................................................................................................1443 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)....................................................1446 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION..................................................................1453 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...............................................1457 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)...........................1459 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS.......................................................................................1463 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS.........................................................................1465 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)..........................................................1468 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED).........................................................1470 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE).......................................................................1474 UNUSUAL NOISE IS HEARD FROM AROUND FAN..........................................................................................1476 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................1477 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................1477 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO.........................................................................1478 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT......................................................................................1479 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..................................1480 ENGINE STARTABILITY IS POOR.....................................................................................................1482 ENGINE DOES NOT PICK UP SMOOTHLY................................................................................................1484 ENGINE STOPS DURING OPERATION...................................................................................................1486 ENGINE RUNS ROUGH OR IS UNSTABLE................................................................................................1488 ENGINE LACKS POWER..............................................................................................................1489 EXHAUST SMOKE IS BLACK..........................................................................................................1491 ENGINE OIL CONSUMPTION IS EXCESSIVE.............................................................................................1493 OIL BECOMES CONTAMINATED QUICKLY................................................................................................1494 FUEL CONSUMPTION IS EXCESSIVE...................................................................................................1495 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...........................................................1496 OIL PRESSURE DROPS..............................................................................................................1497 FUEL MIXES INTO ENGINE OIL......................................................................................................1498 WATER MIXES INTO ENGINE OIL (MILKY).............................................................................................1499 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)................................................................................1500 UNUSUAL NOISE IS HEARD..........................................................................................................1501 VIBRATION IS EXCESSIVE..........................................................................................................1502 AIR CANNOT BE BLED FROM FUEL CIRCUIT............................................................................................1503 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1505 CONTENTS............................................................................................................................1506 ABBREVIATION LIST...................................................................................................................1509 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................1514 HOW TO READ THIS MANUAL.........................................................................................................1514 COATING MATERIALS LIST..........................................................................................................1516 SPECIAL TOOLS LIST..............................................................................................................1521 SKETCHES OF SPECIAL TOOLS.......................................................................................................1531 PREPARATION.........................................................................................................................1536 DRAIN AND ADD COOLANT...........................................................................................................1536 DRAIN COOLANT...............................................................................................................1536 ADD COOLANT.................................................................................................................1537 DRAIN AND ADD HYDRAULIC OIL.....................................................................................................1539 DRAIN HYDRAULIC OIL.........................................................................................................1539 ADD HYDRAULIC OIL...........................................................................................................1540 DRAIN AND ADD FUEL..............................................................................................................1543 DRAIN FUEL..................................................................................................................1543 ADD FUEL....................................................................................................................1544 COLLECT AND REFILL REFRIGERANT..................................................................................................1547 COLLECT REFRIGERANT.........................................................................................................1547 REFILL REFRIGERANT..........................................................................................................1547 ENGINE AND COOLING SYSTEM...........................................................................................................1548 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................1548 REMOVE SUPPLY PUMP ASSEMBLY.................................................................................................1549 INSTALL SUPPLY PUMP ASSEMBLY................................................................................................1553 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................1557 REMOVE INJECTOR ASSEMBLY....................................................................................................1558 INSTALL INJECTOR ASSEMBLY...................................................................................................1562 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................1569 REMOVE CYLINDER HEAD ASSEMBLY...............................................................................................1572 INSTALL CYLINDER HEAD ASSEMBLY..............................................................................................1582 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................1601 REMOVE RADIATOR ASSEMBLY....................................................................................................1601 INSTALL RADIATOR ASSEMBLY...................................................................................................1604 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................1607 REMOVE HYDRAULIC OIL COOLER ASSEMBLY........................................................................................1608 INSTALL HYDRAULIC OIL COOLER ASSEMBLY.......................................................................................1611 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................1614 REMOVE AFTERCOOLER ASSEMBLY.................................................................................................1614 INSTALL AFTERCOOLER ASSEMBLY................................................................................................1616 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................1619 REMOVE ENGINE AND MAIN PUMP ASSEMBLY........................................................................................1620 INSTALL ENGINE AND MAIN PUMP ASSEMBLY.......................................................................................1635 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................1651 REMOVE ENGINE FRONT OIL SEAL................................................................................................1651 INSTALL ENGINE FRONT OIL SEAL...............................................................................................1653 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................1656 REMOVE ENGINE REAR OIL SEAL.................................................................................................1656 INSTALL ENGINE REAR OIL SEAL................................................................................................1658 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................1662 REMOVE ENGINE HOOD ASSEMBLY.................................................................................................1662 INSTALL ENGINE HOOD ASSEMBLY................................................................................................1664 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................1666 REMOVE FUEL TANK ASSEMBLY...................................................................................................1667 INSTALL FUEL TANK ASSEMBLY..................................................................................................1671 POWER TRAIN.........................................................................................................................1677 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................1677 REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY................................................................................1677 INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...............................................................................1679 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................1681 DISASSEMBLE FINAL DRIVE ASSEMBLY............................................................................................1682 ASSEMBLE FINAL DRIVE ASSEMBLY...............................................................................................1687 REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY....................................................................1699 REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY.............................................................................1700 INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................................1702 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................1706 DISASSEMBLE SWING MACHINERY ASSEMBLY........................................................................................1707 ASSEMBLE SWING MACHINERY ASSEMBLY...........................................................................................1713 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................1722 REMOVE SWING CIRCLE ASSEMBLY................................................................................................1722 INSTALL SWING CIRCLE ASSEMBLY...............................................................................................1722 UNDERCARRIAGE AND FRAME.............................................................................................................1724 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................1724 SEPARATE TRACK ASSEMBLY.....................................................................................................1724 INSTALL TRACK ASSEMBLY......................................................................................................1726 REMOVE AND INSTALL SPROCKET.....................................................................................................1730 REMOVE SPROCKET.............................................................................................................1730 INSTALL SPROCKET............................................................................................................1730 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................1732 REMOVE IDLER AND IDLER CUSHION ASSEMBLY.....................................................................................1732 INSTALL IDLER AND IDLER CUSHION ASSEMBLY....................................................................................1733 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................1734 DISASSEMBLE IDLER ASSEMBLY..................................................................................................1734 ASSEMBLE IDLER ASSEMBLY.....................................................................................................1736 DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY.................................................................................1743 DISASSEMBLE IDLER CUSHION ASSEMBLY..........................................................................................1744 ASSEMBLE IDLER CUSHION ASSEMBLY.............................................................................................1745 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................1747 DISASSEMBLE TRACK ROLLER ASSEMBLY...........................................................................................1747 ASSEMBLE TRUCK ROLLER ASSEMBLY..............................................................................................1748 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY................................................................................1750 DISASSEMBLE CARRIER ROLLER ASSEMBLY.........................................................................................1750 ASSEMBLE CARRIER ROLLER ASSEMBLY............................................................................................1752 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................1755 REMOVE REVOLVING FRAME ASSEMBLY.............................................................................................1756 INSTALL REVOLVING FRAME ASSEMBLY............................................................................................1759 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................1762 REMOVE COUNTERWEIGHT ASSEMBLY...............................................................................................1762 INSTALL COUNTERWEIGHT ASSEMBLY..............................................................................................1763 HYDRAULIC SYSTEM....................................................................................................................1765 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................1765 REMOVE CENTER SWIVEL JOINT ASSEMBLY.........................................................................................1766 INSTALL CENTER SWIVEL JOINT ASSEMBLY........................................................................................1769 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................1773 DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY....................................................................................1773 ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY.......................................................................................1774 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................1777 REMOVE HYDRAULIC TANK ASSEMBLY..............................................................................................1778 INSTALL HYDRAULIC TANK ASSEMBLY.............................................................................................1782 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................1789 REMOVE MAIN PUMP ASSEMBLY...................................................................................................1790 INSTALL MAIN PUMP ASSEMBLY..................................................................................................1797 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................1807 REMOVE CONTROL VALVE ASSEMBLY...............................................................................................1808 INSTALL CONTROL VALVE ASSEMBLY..............................................................................................1820 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................1833 REPLACE PRESSURE COMPENSATION VALVE SEAL RING...............................................................................1833 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................1836 DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...............................................................................1836 ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................................1836 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................1839 DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY.......................................................................................1839 ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..........................................................................................1840 WORK EQUIPMENT......................................................................................................................1842 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................1842 REMOVE WORK EQUIPMENT ASSEMBLY..............................................................................................1843 INSTALL WORK EQUIPMENT ASSEMBLY.............................................................................................1846 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................1849 DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY................................................................................1850 ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................................1855 CAB RELATED PARTS...................................................................................................................1864 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY........................................................................................1864 REMOVE OPERATOR CAB ASSEMBLY................................................................................................1865 INSTALL OPERATOR CAB ASSEMBLY...............................................................................................1875 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................1885 REMOVE OPERATOR CAB GLASS (ADHERED GLASS)...................................................................................1887 INSTALL OPERATOR CAB GLASS (ADHERED GLASS)..................................................................................1887 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................1898 REMOVE FRONT WINDOW ASSEMBLY................................................................................................1898 INSTALL FRONT WINDOW ASSEMBLY...............................................................................................1901 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................1907 REMOVE FLOOR FRAME ASSEMBLY.................................................................................................1908 INSTALL FLOOR FRAME ASSEMBLY................................................................................................1914 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................1922 REMOVE AIR CONDITIONER UNIT ASSEMBLY........................................................................................1923 INSTALL AIR CONDITIONER UNIT ASSEMBLY.......................................................................................1931 REMOVE AND INSTALL OPERATOR SEAT................................................................................................1939 REMOVE OPERATOR SEAT........................................................................................................1939 INSTALL OPERATOR SEAT.......................................................................................................1940 REMOVE AND INSTALL SEATBELT.....................................................................................................1942 REMOVE SEATBELT.............................................................................................................1942 INSTALL SEATBELT............................................................................................................1943 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY........................................................................1944 REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY................................................................................1944 INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY...............................................................................1949 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................1957 REMOVE FRONT WIPER ASSEMBLY.................................................................................................1957 INSTALL FRONT WIPER ASSEMBLY................................................................................................1962 ELECTRICAL SYSTEM...................................................................................................................1970 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................1970 REMOVE ENGINE CONTROLLER ASSEMBLY...........................................................................................1971 INSTALL ENGINE CONTROLLER ASSEMBLY..........................................................................................1972 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................1974 REMOVE PUMP CONTROLLER ASSEMBLY.............................................................................................1974 INSTALL PUMP CONTROLLER ASSEMBLY............................................................................................1976 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................1980 REMOVE MACHINE MONITOR ASSEMBLY.............................................................................................1980 INSTALL MACHINE MONITOR ASSEMBLY............................................................................................1983 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................1987 REMOVE KOMTRAX TERMINAL ASSEMBLY............................................................................................1987 INSTALL KOMTRAX TERMINAL ASSEMBLY...........................................................................................1990 60 MAINTENANCE STANDARD.................................................................................................................1993 CONTENTS............................................................................................................................1994 ABBREVIATION LIST...................................................................................................................1995 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.......................................................................................2000 ENGINE AND COOLING SYSTEM...........................................................................................................2002 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2002 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2003 POWER TRAIN.........................................................................................................................2004 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2004 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2005 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2008 MAINTENANCE STANDARD OF SPROCKET................................................................................................2010 SPROCKET TOOTH PROFILE FULL-SCALE DRAWING.......................................................................................2011 UNDERCARRIAGE AND FRAME.............................................................................................................2012 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2012 MAINTENANCE STANDARD OF IDLER...................................................................................................2013 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2015 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2017 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2018 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2021 MAINTENANCE STANDARD OF SWAMP SHOE..............................................................................................2022 MAINTENANCE STANDARD OF ROAD LINER..............................................................................................2023 HYDRAULIC SYSTEM....................................................................................................................2024 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2024 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2025 MAINTENANCE STANDARD OF LS-EPC VALVE............................................................................................2027 MAINTENANCE STANDARD OF PC-EPC VALVE............................................................................................2028 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2029 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2031 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2034 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2044 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2047 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2050 MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE..................................................................2051 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................2052 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2053 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...................................................2055 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)....................................................2056 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2057 WORK EQUIPMENT......................................................................................................................2058 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2058 DIMENSIONS OF ARM...............................................................................................................2064 DIMENSIONS OF BUCKET............................................................................................................2066 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2068 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2069 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2070 80 OTHERS...............................................................................................................................2071 CONTENTS............................................................................................................................2072 ABBREVIATION........................................................................................................................2074 AIR CONDITIONER SYSTEM..............................................................................................................2079 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2079 LAYOUT DRAWING OF AIR CONDITIONER SYSTEM........................................................................................2080 SPECIFICATION OF AIR CONDITIONER................................................................................................2082 CONFIGURATION OF REFRIGERATION CYCLE............................................................................................2083 FUNCTION OF REFRIGERATION CYCLE.................................................................................................2084 SYSTEM DIAGRAM OF AIR CONDITIONER...................................................................................................2085 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2086 AIR CONDITIONER UNIT............................................................................................................2086 STRUCTURE OF AIR CONDITIONER UNIT...........................................................................................2087 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2088 COMPONENT PARTS OF AIR CONDITIONER UNIT.....................................................................................2089 AIR CONDITIONER CONTROLLER......................................................................................................2093 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2093 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2093 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER......................................................................2093 COMPRESSOR......................................................................................................................2095 STRUCTURE OF COMPRESSOR.....................................................................................................2095 SPECIFICATIONS OF COMPRESSOR................................................................................................2095 FUNCTION OF COMPRESSOR......................................................................................................2095 OPERATION OF COMPRESSOR.....................................................................................................2095 CONDENSER.......................................................................................................................2096 STRUCTURE OF CONDENSER......................................................................................................2096 SPECIFICATIONS OF CONDENSOR.................................................................................................2096 FUNCTION OF COMPRESSOR......................................................................................................2096 AIR CONDITIONER RELATED SENSORS.................................................................................................2098 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2098 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2098 STRUCTURE OF OUTSIDE TEMPERATURE SENSOR.....................................................................................2098 FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR..................................................................................2098 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER................................................................2099 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2101 TEST AIR LEAKAGE (DUCT CONNECTION)..................................................................................................2105 TEST AIR LEAKAGE (DUCT CONNECTION)..............................................................................................2105 TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION.....................................................................................2108 TEST VENT (MODE) CHANGEOVER.........................................................................................................2109 TEST VENT (MODE) CHANGEOVER.....................................................................................................2109 TEST FRESH/RECIRC AIR CHANGEOVER....................................................................................................2111 TEST FRESH/RECIRC AIR CHANGEOVER................................................................................................2111 TEST SUNLIGHT SENSOR................................................................................................................2112 TEST SUNLIGHT SENSOR............................................................................................................2112 TEST DUAL PRESSURE SWITCH...........................................................................................................2113 TEST DUAL PRESSURE SWITCH.......................................................................................................2113 TEST RELAY..........................................................................................................................2114 TEST RELAY......................................................................................................................2114 SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS..............................................................................2116 PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER...................................................................................2117 INFORMATION DESCRIBED IN TROUBLESHOOTING............................................................................................2118 FAILURE CODE [879AKA]...............................................................................................................2121 FAILURE CODE [879AKB]...............................................................................................................2123 FAILURE CODE [879BKA]...............................................................................................................2125 FAILURE CODE [879BKB]...............................................................................................................2128 FAILURE CODE [879CKA]...............................................................................................................2131 FAILURE CODE [879CKB]...............................................................................................................2133 FAILURE CODE [879DKZ]...............................................................................................................2135 FAILURE CODE [879EMC]...............................................................................................................2138 FAILURE CODE [879FMC]...............................................................................................................2140 FAILURE CODE [879GKX]...............................................................................................................2142 AIR CONDITIONER DOES NOT OPERATE....................................................................................................2145 DEFECTIVE COOLING...................................................................................................................2148 HEATER DOES NOT OPERATE.............................................................................................................2157 COOL AIR DOES NOT COME OUT..........................................................................................................2161 NO AIR COMES OUT OR AIR FLOW IS ABNORMAL............................................................................................2168 FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE............................................................................................2172 CONNECT SERVICE TOOL................................................................................................................2176 CONNECT SERVICE TOOL............................................................................................................2177 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING..............................................................2178 HANDLE COMPRESSOR OIL...............................................................................................................2180 REPLACE DESICCANT...................................................................................................................2182 90 CIRCUIT DIAGRAMS.....................................................................................................................2185 CONTENTS............................................................................................................................2186 ABBREVIATION LIST...................................................................................................................2187 HOW TO READ THE CODES FOR ELECTRIC CABLE............................................................................................2192 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2196 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2196 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................2201 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2203 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM........................................................................................2203 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (1/7)..........................................................2207 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (2/7)..........................................................2209 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (3/7)..........................................................2211 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (4/7)..........................................................2213 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (5/7)..........................................................2215 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (6/7)..........................................................2217 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700001 to 700005) (7/7)..........................................................2219 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (1/7).............................................................2221 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (2/7).............................................................2223 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (3/7).............................................................2225 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (4/7).............................................................2227 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (5/7).............................................................2229 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (6/7).............................................................2231 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:700006 and up) (7/7).............................................................2233 INDEX....................................................................................................................................2235
DESCRIPTION:
KOMATSU PC200-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06867-07 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 02/01/2025
