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KOMATSU PC2000-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06651-14 – PDF DOWNLOAD
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KOMATSU PC2000-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06651-14 – PDF DOWNLOAD
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KOMATSU PC2000-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06651-14 – PDF DOWNLOAD
Language : English
Pages : 4178
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC2000-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06651-14 – PDF DOWNLOAD
Cover...................................................................................................................................................... 1 00 Index and Foreword................................................................................................................................. 3 Index............................................................................................................................................. 4 Abbreviation List................................................................................................................................. 25 Foreword, Safety, Basic Information............................................................................................................... 28 How to Read the Shop Manual................................................................................................................... 28 Safety Notice for Operation................................................................................................................... 30 Precautions to Prevent Fire................................................................................................................... 38 Procedures If Fire Occurs..................................................................................................................... 40 Precautions When You Discard Waste Materials.................................................................................................. 41 Precautions When You Handle Hydraulic Equipment............................................................................................... 42 Precautions When You Disconnect and Connect Pipings........................................................................................... 45 Precautions When You Handle Electrical Equipment.............................................................................................. 51 Precautions When You Handle Fuel System Equipment............................................................................................. 53 Precautions When You Handle Intake System Equipment........................................................................................... 54 Practical Use of KOMTRAX...................................................................................................................... 55 Disconnect and Connect Push-Pull Type Coupler................................................................................................. 56 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................... 56 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................... 57 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................... 58 Precautions for Disconnection and Connection of Connectors.................................................................................... 60 How to Disconnect and Connect Deutsch Connector............................................................................................... 64 How to Disconnect and Connect Slide Lock Type Connector....................................................................................... 65 How to Disconnect and Connect Connector with Lock to Pull..................................................................................... 67 How to Disconnect and Connect Connector with Lock to Push..................................................................................... 68 How to Disconnect and Connect Connector with Housing to Rotate................................................................................ 70 How to Read the Codes for Electric Cable...................................................................................................... 71 Explanation of Terms for Maintenance Standard................................................................................................. 75 Standard Tightening Torque Table.............................................................................................................. 78 Conversion Table.............................................................................................................................. 85 01 Specifications..................................................................................................................................... 91 Table of Contents................................................................................................................................. 92 Specifications.................................................................................................................................... 93 Specification Drawing......................................................................................................................... 93 Specification Drawing: PC2000-11.......................................................................................................... 93 Specification Drawing: PC2000-11 (Loading Shovel Specification)........................................................................... 94 Working Range Drawings........................................................................................................................ 96 Working Range Drawings: PC2000-11......................................................................................................... 96 Working Range Drawings: PC2000-11 (Loading Shovel Specification).......................................................................... 97 Specifications................................................................................................................................ 98 Specification: PC2000-11.................................................................................................................. 98 Specifications: PC2000-11 (Loading Shovel Specification).................................................................................. 101 Weight Table.................................................................................................................................. 105 Weight Table: PC2000-11................................................................................................................... 105 Weight Table: PC2000-11 (Loading Shovel Specification).................................................................................... 108 Fuel, Coolant, Lubricants (For North America)................................................................................................. 112 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 112 10 Structure and Function............................................................................................................................. 115 Table of Contents................................................................................................................................. 116 Boot-up System.................................................................................................................................... 120 Layout Drawing of Boot-up System.............................................................................................................. 120 System Operating Lamp System.................................................................................................................. 121 System Diagram of System Operating Lamp System............................................................................................ 121 Function of Operation Lamp System......................................................................................................... 121 Battery Isolator.............................................................................................................................. 123 Layout Drawing of Battery Isolator........................................................................................................ 123 Function of Battery Isolator.............................................................................................................. 123 Function of Starting Motor Isolator Switch................................................................................................ 124 Engine System..................................................................................................................................... 125 Layout Drawing of Engine System............................................................................................................... 125 Function of Engine System................................................................................................................. 126 Engine Control System......................................................................................................................... 127 System Diagram of Engine Control.......................................................................................................... 127 Operation of Engine Control System........................................................................................................ 128 Auto-Deceleration System...................................................................................................................... 129 System Diagram of Auto-Deceleration System................................................................................................ 129 Function of Auto-Deceleration System...................................................................................................... 130 Operation of Auto-Deceleration System..................................................................................................... 130 Automatic Low Idle System..................................................................................................................... 131 Automatic Low Idle System Diagram......................................................................................................... 131 Function of Automatic Low Idle System..................................................................................................... 131 Operation of Automatic Low Idle System.................................................................................................... 132 Engine Automatic Warm-up System............................................................................................................... 133 System Diagram of Engine Automatic Warm-up System......................................................................................... 133 Function of Engine Automatic Warm-up System............................................................................................... 134 Overheat Prevention System.................................................................................................................... 135 Overheat Prevention System Diagram........................................................................................................ 135 Function of Overheat Prevention System.................................................................................................... 136 Turbocharger Protection System................................................................................................................ 137 System Diagram of Turbocharger Protection System.......................................................................................... 137 Function of Turbocharger Protection System................................................................................................ 137 Multiple Injection Control System............................................................................................................. 139 Function of Multiple Injection Control System............................................................................................. 139 Component Parts of Engine System.............................................................................................................. 140 PTO....................................................................................................................................... 140 VGT....................................................................................................................................... 143 EGR System................................................................................................................................ 147 EGR Valve................................................................................................................................. 151 EGR Cooler................................................................................................................................ 153 KCCV System............................................................................................................................... 154 KCCV Ventilator........................................................................................................................... 157 KDPF...................................................................................................................................... 159 Cooling System.................................................................................................................................... 163 Layout Drawing of Cooling System.............................................................................................................. 163 Specifications of Cooling System.......................................................................................................... 164 Fan Speed Control System of Hydraulic Fan..................................................................................................... 165 Fan Speed Control System Diagram of Hydraulic Fan......................................................................................... 165 Function of Fan Speed Control System of Hydraulic Fan..................................................................................... 166 Engine Output Control System of Hydraulic Fan................................................................................................. 167 Engine Output Control System Diagram of Hydraulic Fan..................................................................................... 167 Function of Engine Output Control System of Hydraulic Fan................................................................................. 167 Fan Reverse Rotation System of Hydraulic Fan.................................................................................................. 168 Fan Reverse Rotation System Diagram of Hydraulic Fan...................................................................................... 168 Function of Fan Reverse Rotation System of Hydraulic Fan.................................................................................. 168 Component Parts of Cooling System............................................................................................................. 169 Cooling Fan Pump.......................................................................................................................... 169 Cooling Fan Motor......................................................................................................................... 183 Control System.................................................................................................................................... 190 Layout Drawing of Control System.............................................................................................................. 190 Machine Monitor System........................................................................................................................ 192 System Diagram of Machine Monitor System.................................................................................................. 192 KOMTRAX Plus System........................................................................................................................... 194 System Diagram of KOMTRAX Plus System..................................................................................................... 194 Function of KOMTRAX Plus System........................................................................................................... 194 Component Parts of Control System............................................................................................................. 199 Machine Monitor........................................................................................................................... 199 KOMTRAX Terminal.......................................................................................................................... 215 KOMTRAX Plus Controller................................................................................................................... 217 Wireless LAN Unit......................................................................................................................... 222 Pump Controller........................................................................................................................... 223 Valve Controller 1........................................................................................................................ 227 Valve Controller 2........................................................................................................................ 231 Resistor for Pump Secondary Drive......................................................................................................... 235 CAN Terminating Resistor.................................................................................................................. 236 Engine Controller......................................................................................................................... 237 Fuel Control Dial......................................................................................................................... 251 Fuel Feed Pump............................................................................................................................ 252 Fuel Feed Pump Switch..................................................................................................................... 253 Hydraulic System.................................................................................................................................. 254 Layout Drawing of Hydraulic System............................................................................................................ 254 Electronic OLSS............................................................................................................................... 257 Structure of Electronic OLSS.............................................................................................................. 257 Function of Electronic OLSS............................................................................................................... 258 Engine and Pump Combined Control System....................................................................................................... 260 Engine and Pump Combined Control System Diagram........................................................................................... 260 Function of Engine and Pump Combined Control System....................................................................................... 261 Component Parts of Hydraulic System........................................................................................................... 264 Hydraulic Tank............................................................................................................................ 264 Main Pump................................................................................................................................. 265 Control Valve............................................................................................................................. 285 Variable Back Pressure Valve.............................................................................................................. 317 Work Equipment System............................................................................................................................. 320 Layout Drawing of Work Equipment System....................................................................................................... 320 Layout Drawing of Work Equipment System (Loading Shovel Specification)........................................................................ 326 Work Equipment System Diagram................................................................................................................. 332 Machine Push-up System........................................................................................................................ 333 Machine Push-up System Diagram............................................................................................................ 333 Function of Machine Push-up System........................................................................................................ 333 Heavy Lift System............................................................................................................................. 335 Heavy Lift System Diagram................................................................................................................. 335 Function of Heavy Lift System............................................................................................................. 335 Operation of Heavy Lift System............................................................................................................ 336 Boom Shockless Control Function............................................................................................................... 337 Boom Shockless Control Function System Diagram............................................................................................ 337 Operation of Boom Shockless Control Function.............................................................................................. 337 PPC Lock System............................................................................................................................... 338 System Diagram of PPC Lock................................................................................................................ 338 Function of PPC Lock System............................................................................................................... 338 Work Equipment and Travel Automatic Lock System............................................................................................... 339 System Diagram of Lock Lever Automatic Lock System........................................................................................ 339 Function of Work Equipment and Travel Automatic Lock System............................................................................... 339 Operation of Lock Lever Automatic Lock System............................................................................................. 339 Component Parts of Work Equipment System...................................................................................................... 341 Work Equipment and Swing PPC Valve........................................................................................................ 341 Suction Selector Valve.................................................................................................................... 347 PPC Cut-off Valve......................................................................................................................... 351 Solenoid Valve............................................................................................................................ 356 Pilot Circuit Accumulator................................................................................................................. 361 Swing System...................................................................................................................................... 362 Layout Drawing of Swing System................................................................................................................ 362 Swing Control System Diagram.................................................................................................................. 365 Function of Swing Control System.......................................................................................................... 365 Swing Priority System Diagram................................................................................................................. 368 Operation of Swing Priority System........................................................................................................ 369 Component Parts of Swing System............................................................................................................... 370 Swing Motor............................................................................................................................... 370 Swing Machinery........................................................................................................................... 380 Swing Circle.............................................................................................................................. 382 Travel System..................................................................................................................................... 383 Layout Drawing of Travel System............................................................................................................... 383 System Diagram of Travel Control System....................................................................................................... 387 Travel Straight System Diagram................................................................................................................ 388 Operation of Travel Straight System....................................................................................................... 389 HIC System.................................................................................................................................... 391 Layout Drawing of HIC System.............................................................................................................. 391 HIC System Diagram........................................................................................................................ 392 Operation of HIC System................................................................................................................... 392 Component Parts of Travel System.............................................................................................................. 395 Travel Motor.............................................................................................................................. 395 Final Drive............................................................................................................................... 408 Travel PPC Valve.......................................................................................................................... 410 Center Swivel Joint....................................................................................................................... 414 Accumulator for HIC System.................................................................................................................... 415 Structure of Accumulator for HIC System................................................................................................... 415 Specifications of Accumulator for HIC System.............................................................................................. 415 Lifting System.................................................................................................................................... 416 Hydraulically Operated Stairway System........................................................................................................ 416 Layout Drawing of Hydraulically Operated Stairway System.................................................................................. 416 Hydraulically Operated Stairway System Diagram............................................................................................ 417 Function of Hydraulically Operated Stairway System........................................................................................ 417 Component Parts of Lifting System............................................................................................................. 418 Switch Box................................................................................................................................ 418 Proximity Switch Part..................................................................................................................... 418 Control Valve Assembly.................................................................................................................... 419 Service Center System............................................................................................................................. 420 Layout Drawing of Service Center System....................................................................................................... 420 Service Center System Diagram................................................................................................................. 422 Function of Service Center System......................................................................................................... 422 Component Parts of Service Center System...................................................................................................... 424 Raise/Lower Switch........................................................................................................................ 424 Proximity Switch Part..................................................................................................................... 424 Control Valve Assembly.................................................................................................................... 425 Left Console Box Section in CAB........................................................................................................... 426 Service Panel Part........................................................................................................................ 426 Grease Lubrication System......................................................................................................................... 429 Grease Lubrication System Diagram............................................................................................................. 429 Function of Grease Lubrication System..................................................................................................... 431 Specifications of Grease Lubrication System............................................................................................... 432 Component Parts of Grease Lubrication System.................................................................................................. 433 Grease Pump............................................................................................................................... 433 Grease Gun................................................................................................................................ 435 Hose Reel................................................................................................................................. 435 Injector Distribution Valve............................................................................................................... 436 Undercarriage and Frame........................................................................................................................... 439 Layout Drawing of Undercarriage............................................................................................................... 439 Specifications of Undercarriage........................................................................................................... 439 Work Equipment.................................................................................................................................... 440 Structure of Work Equipment................................................................................................................... 440 Structure of Work Equipment (Loading Shovel Specification).................................................................................... 441 Function of Work Equipment.................................................................................................................... 442 Work Equipment Clearance Adjustment Shim...................................................................................................... 443 Function of Work Equipment Clearance Adjustment Shim...................................................................................... 443 CAB Related Parts................................................................................................................................. 444 CAB........................................................................................................................................... 444 Structure of CAB.......................................................................................................................... 444 Wiper System.................................................................................................................................. 445 Layout Drawing of Wiper System............................................................................................................ 445 Wiper System Diagram...................................................................................................................... 446 Function of Wiper System.................................................................................................................. 446 CAB Mount..................................................................................................................................... 449 Structure of CAB Mount.................................................................................................................... 449 Function of CAB Mount..................................................................................................................... 449 20 Standard Value Table............................................................................................................................... 451 Table of Contents................................................................................................................................. 452 Standard Value Table for Engine................................................................................................................... 453 Standard Value Table for Engine: PC2000-11.................................................................................................... 453 Standard Value Table for Machine.................................................................................................................. 458 Standard Value Table for Machine: PC2000-11 (Backhoe Specification)........................................................................... 458 Standard Value Table for Machine: PC2000-11 (Loading Shovel Specification).................................................................... 475 Machine Posture and Procedures to Measure Performance (Backhoe Specification)................................................................. 494 Machine Posture and Procedures to Measure Performance (Loading Shovel Specification).......................................................... 497 30 Testing and Adjusting.............................................................................................................................. 501 Table of Contents................................................................................................................................. 502 Precautions Before Work........................................................................................................................... 506 Related Information on Testing and Adjusting...................................................................................................... 507 Tools for Testing and Adjusting............................................................................................................... 507 Engine and Cooling System......................................................................................................................... 515 Examine Engine Speed.......................................................................................................................... 515 How to Examine Engine Speed............................................................................................................... 515 Examine Boost Pressure........................................................................................................................ 518 How to Examine Boost Pressure on Machine Monitor.......................................................................................... 518 How to Examine Boost Pressure by Testing Tool............................................................................................. 519 Examine Exhaust Gas Temperature............................................................................................................... 522 How to Examine Exhaust Gas Temperature.................................................................................................... 522 Examine Exhaust Gas Color..................................................................................................................... 523 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................. 523 How to Examine Exhaust Gas Color with Smoke Meter......................................................................................... 526 Examine Mass Air Flow and Temperature Sensor.................................................................................................. 529 How to Examine Mass Air Flow and Temperature Sensor....................................................................................... 529 Examine and Adjust Valve Clearance............................................................................................................ 534 How to Examine Valve Clearance............................................................................................................ 534 How to Adjust Valve Clearance............................................................................................................. 535 Examine Compression Pressure.................................................................................................................. 537 How to Examine Compression Pressure....................................................................................................... 537 Examine Blowby Pressure....................................................................................................................... 541 How to Examine Blowby Pressure by Testing Tool............................................................................................ 541 Examine Engine Oil Pressure................................................................................................................... 547 How to Examine Engine Oil Pressure on Machine Monitor..................................................................................... 547 How to Examine Engine Oil Pressure by Testing Tool........................................................................................ 547 Examine EGR Valve and VGT Oil Pressure........................................................................................................ 549 How to Examine EGR Valve and VGT Oil Pressure............................................................................................. 549 Examine Fuel Pressure......................................................................................................................... 551 How to Examine Fuel Pressure.............................................................................................................. 551 Examine Fuel Return Rate and Leakage.......................................................................................................... 553 How to Examine Fuel Return Rate and Leakage............................................................................................... 554 Bleed Air from Fuel System.................................................................................................................... 559 How to Bleed Air from Fuel System......................................................................................................... 560 Examine Fuel Circuit for Leakage.............................................................................................................. 562 How to Examine Fuel System for Leakage.................................................................................................... 562 Examine Supply Pump........................................................................................................................... 564 How to Examine Supply Pump................................................................................................................ 564 Handle Cylinder Cut-out Mode Operation........................................................................................................ 568 Examine Alternator............................................................................................................................ 569 How to Examine Alternator................................................................................................................. 569 Examine and Adjust Alternator Belt Tension.................................................................................................... 570 How to Examine Alternator Belt Tension.................................................................................................... 570 How to Adjust Tension of Alternator Belt.................................................................................................. 571 Handle No-Injection Cranking Operation........................................................................................................ 572 Examine and Adjust Air Conditioner Compressor Belt Tension.................................................................................... 573 How to Examine Air Conditioner Compressor Belt Tension.................................................................................... 573 How to Adjust Air Conditioner Compressor Belt Tension..................................................................................... 574 Clean Fuel Doser.............................................................................................................................. 575 How to Clean Fuel Doser................................................................................................................... 575 Write Injector Compensation Value to Engine Controller........................................................................................ 578 How to Write Injector Compensation Value.................................................................................................. 578 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................................ 584 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................. 584 Power Train....................................................................................................................................... 585 Examine Swing Circle Bearing Clearance........................................................................................................ 585 How to Examine Swing Circle Bearing Clearance............................................................................................. 585 Release Remained Pressure from HIC Circuit.................................................................................................... 586 How to Release Remained Pressure from HIC Circuit......................................................................................... 586 Examine and Charge HIC Circuit Accumulator Nitrogen Gas Pressure.............................................................................. 587 How to Examine HIC Circuit Accumulator Nitrogen Gas....................................................................................... 587 How to Charge HIC Circuit Accumulator Nitrogen Gas........................................................................................ 590 Bleed Air from HIC Circuit.................................................................................................................... 593 How to Bleed Air from HIC Circuit......................................................................................................... 593 Undercarriage and Frame........................................................................................................................... 595 Examine Sprocket Wear......................................................................................................................... 595 How to Examine Sprocket Wear.............................................................................................................. 595 Examine and Adjust Track Tension.............................................................................................................. 596 How to Examine Track Tension.............................................................................................................. 596 How to Adjust Track Tension............................................................................................................... 596 Hydraulic System.................................................................................................................................. 599 Release Remained Pressure in Hydraulic Circuit................................................................................................ 599 How to Release Remained Pressure in Hydraulic System...................................................................................... 599 How to Release Remained Pressure from Hydraulic Tank...................................................................................... 599 How to Release Remained Pressure in Hydraulic Cylinder Circuit............................................................................ 599 How to Release Remained Pressure from Swing Motor Circuit................................................................................. 599 How to Release Remained Pressure from Travel Motor Circuit................................................................................ 600 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits................................................................. 601 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits................................................................. 604 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits.................................................................. 611 Examine and Adjust Oil Pressure in Control Circuit............................................................................................ 615 How to Examine Oil Pressure in Control Circuit............................................................................................ 615 How to Adjust Oil Pressure in Control Circuit............................................................................................. 616 Examine Pump EPC Solenoid Valve Outlet Pressure............................................................................................... 617 How to Examine Pump EPC Solenoid Valve Outlet Pressure.................................................................................... 617 How to Examine Pump EPC Solenoid Valve Electric Current................................................................................... 618 Examine and Adjust Jet Sensor Differential Pressure........................................................................................... 619 How to Examine Jet Sensor Differential Pressure with Machine Monitor...................................................................... 619 How to Examine Jet Sensor Differential Pressure by Testing Tool........................................................................... 620 How to Examine Jet Sensor Differential Pressure........................................................................................... 621 How to Adjust Jet Sensor Differential Pressure............................................................................................ 621 Examine Outlet Pressure of Solenoid Valve..................................................................................................... 623 How to Examine Outlet Pressure of Solenoid Valve.......................................................................................... 623 Operating Condition of Solenoid Valve..................................................................................................... 625 Examine Outlet Pressure of EPC Solenoid Valve................................................................................................. 627 How to Examine Outlet Pressure of EPC Solenoid Valve...................................................................................... 627 Examine PPC Valve Outlet Pressure............................................................................................................. 629 How to Examine Outlet Pressure in PPC Valve............................................................................................... 630 Adjust Play of Work Equipment and Swing PPC Valves............................................................................................ 632 How to Adjust Play of Work Equipment and Swing PPC Valves................................................................................. 632 Examine Travel Deviation...................................................................................................................... 633 How to Examine Travel Deviation........................................................................................................... 633 How to Adjust Travel Deviation............................................................................................................ 633 Examine Fan Speed............................................................................................................................. 634 How to Examine Radiator Fan Speed......................................................................................................... 634 How to Examine Oil Cooler Fan Speed....................................................................................................... 634 Examine Oil Pressure in Fan Pump Circuit...................................................................................................... 635 How to Examine Radiator Fan Pump Circuit Oil Pressure by Machine Monitor.................................................................. 635 How to Examine Radiator Fan Pump Circuit Oil Pressure by Testing Tool..................................................................... 635 How to Examine Oil Cooler Fan Pump Circuit Oil Pressure by Machine Monitor................................................................ 636 How to Examine Oil Cooler Fan Pump Circuit Oil Pressure by Testing Tool................................................................... 636 Examine Fan Pump EPC Electric Current......................................................................................................... 638 How to Examine Radiator Fan Pump EPC Electric Current..................................................................................... 638 How to Examine Oil Cooler Fan Pump EPC Electric Current................................................................................... 638 Examine Fan Pump EPC Solenoid Valve Outlet Pressure........................................................................................... 639 How to Examine Radiator Fan Pump EPC Solenoid Valve Outlet Pressure....................................................................... 639 How to Examine Outlet Pressure of EPC Solenoid Valve of Oil Cooler Fan Pump............................................................... 640 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................................... 641 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder..................................................... 641 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder...................................................................... 641 How to Examine Parts that Cause Hydraulic Drift of PPC Valve.............................................................................. 642 Examine Oil Leakage........................................................................................................................... 643 How to Examine Oil Leakage from Boom Cylinder............................................................................................. 643 How to Examine Oil Leakage from Arm Cylinder.............................................................................................. 644 How to Examine Oil Leakage from Bucket Cylinder........................................................................................... 644 How to Examine Oil Leakage from Swing Motor............................................................................................... 645 How to Examine Oil Leakage from Travel Motor.............................................................................................. 645 How to Examine Oil Leakage of Swivel Joint................................................................................................ 646 Bleed Air from Hydraulic System............................................................................................................... 648 How to Bleed Air from Hydraulic System.................................................................................................... 649 CAB Related Parts................................................................................................................................. 656 How to Adjust Mirrors......................................................................................................................... 656 Procedure to Adjust Machine Left Front Mirror (A)......................................................................................... 656 Procedure to Adjust Regular Position of Machine Left Front Mirror (A)..................................................................... 657 Procedure to Adjust Machine Left Front Mirror (B)......................................................................................... 658 Procedure to Adjust Regular Position of Machine Left Front Mirror (B)..................................................................... 658 Procedure to Adjust Machine Left Rear Mirror (C).......................................................................................... 659 Procedure to Adjust Regular Position of Machine Left Rear Mirror (C)...................................................................... 660 Procedure to Adjust Machine Right Center Mirror (D)....................................................................................... 661 Procedure to Adjust Regular Position of Machine Right Center Mirror (D)................................................................... 661 Automatic Lubrication System...................................................................................................................... 664 Examine and Adjust Automatic Lubrication System............................................................................................... 664 How to Examine Auto-Greasing System....................................................................................................... 664 How to Adjust Automatic Lubrication System................................................................................................ 666 Lifting System.................................................................................................................................... 668 Examine and Adjust Hydraulically Operated Stairway Proximity Switch........................................................................... 668 How to Examine Clearance of Hydraulically Operated Stairway Proximity Switch.............................................................. 668 How to Adjust Clearance of Hydraulically Operated Stairway Proximity Switch............................................................... 669 How to Examine Position of Hydraulically Operated Stairway Position Detecting Plate....................................................... 670 How to Adjust Position of Hydraulically Operated Stairway Position Detecting Plate........................................................ 670 Service Center System............................................................................................................................. 672 Examine and Adjust Service Arm Proximity Switch............................................................................................... 672 How to Examine Clearance of Service Arm Proximity Switch.................................................................................. 672 How to Adjust Clearance of Service Arm Proximity Switch................................................................................... 672 Electrical System................................................................................................................................. 673 Set and Operate Machine Monitor............................................................................................................... 673 Operator Mode............................................................................................................................. 677 Function to Show Technician Identification Status Screen.................................................................................. 677 Function to Show Operator Identification Input Screen..................................................................................... 677 Examine Function by LCD (Liquid Crystal Display).......................................................................................... 678 Examine Function of Service Meter......................................................................................................... 678 Usage Limitation and Maintenance Password Change Function................................................................................. 678 Service Mode.............................................................................................................................. 681 How to Operate Service Mode............................................................................................................... 681 How to See Pre-defined Monitoring Information............................................................................................. 684 How to Examine Self-Define Monitor Information............................................................................................ 694 Abnormality Record Menu................................................................................................................... 709 How to See Maintenance Record............................................................................................................. 713 Maintenance Mode Setting.................................................................................................................. 714 How to Set Phone Number Entry............................................................................................................. 718 Default Menu.............................................................................................................................. 720 Diagnostic Tests Menu..................................................................................................................... 728 Adjustment Menu........................................................................................................................... 740 No-Injection Cranking Operation........................................................................................................... 758 Machine Configuration Menu................................................................................................................ 760 KOMTRAX Settings Menu..................................................................................................................... 763 How to Show Service Message............................................................................................................... 765 How to Operate Snap Shot.................................................................................................................. 766 How to Handle Snap Shot (Quick Pm)........................................................................................................ 767 How to Start Up KOMTRAX Terminal.............................................................................................................. 769 How to Stop Use of KOMTRAX Terminal........................................................................................................... 774 Default Setting of KOMTRAX Plus Controller.................................................................................................... 776 How to do the Default Setting of KOMTRAX Plus Controller.................................................................................. 776 Default Setting of Wireless LAN Modem......................................................................................................... 779 Default Setting of Wireless LAN Modem..................................................................................................... 779 How to Examine Wireless LAN Modem Communication........................................................................................... 780 Download Data from KOMTRAX Plus Controller.................................................................................................... 782 How to Download Data from KOMTRAX Plus Controller......................................................................................... 782 Adjust After Replacement of KOMTRAX Plus Controller........................................................................................... 785 How to Adjust After Replacement of KOMTRAX Plus Controller................................................................................ 785 Adjust After Replacement of Wireless LAN Modem................................................................................................ 788 How to Adjust After Replacement of Wireless LAN Modem..................................................................................... 788 Adjust KomVision Camera Angle................................................................................................................. 791 How to Adjust KomVision Camera Angle...................................................................................................... 791 Set Region of Bluetooth(R) Compatible Radio................................................................................................... 794 How to Set Region of Bluetooth(R) Compatible Radio........................................................................................ 794 Handle Voltage Circuit of Engine Controller................................................................................................... 796 Handle Battery Isolator and Starting Motor Isolator........................................................................................... 797 Examine Diodes................................................................................................................................ 798 How to Examine Diodes by Digital Tester................................................................................................... 798 How to Examine Diodes by Analog Tester.................................................................................................... 798 Pm Clinic......................................................................................................................................... 799 Pm Clinic Service............................................................................................................................. 799 Pm Clinic Check Sheet: PC2000-11 (Backhoe Specification).................................................................................. 804 Pm Clinic Check Sheet: PC2000-11 (Loading Shovel Specification)........................................................................... 817 Perform Quick Pm.............................................................................................................................. 831 How to Perform Quick Pm................................................................................................................... 831 40 Troubleshooting.................................................................................................................................... 837 Table of Contents................................................................................................................................. 838 Precautions Before Work........................................................................................................................... 851 Related Information to Troubleshooting............................................................................................................ 852 General Troubleshooting Points................................................................................................................ 852 Troubleshooting Points for Aftertreatment System.............................................................................................. 853 Sequence of Events in Troubleshooting......................................................................................................... 860 Checks Before Troubleshooting................................................................................................................. 862 Inspection Procedure Before Troubleshooting................................................................................................... 864 Walk-Around Check......................................................................................................................... 864 Test in Accordance with Testing Procedure..................................................................................................... 866 Examine Fuel Level and Type............................................................................................................... 866 Examine for Impure Ingredient in Fuel..................................................................................................... 866 Examine Fuel Prefilter.................................................................................................................... 867 Examine Water Separator, Drain Water and Sediment......................................................................................... 867 Replace Fuel Prefilter Cartridge.......................................................................................................... 868 Examine Fuel Main Filter.................................................................................................................. 869 Examine Engine Oil Level (Oil Quantity in Oil Pan)........................................................................................ 871 Examine Coolant Level (Reservoir Tank).................................................................................................... 873 Examine Air Cleaner Clogging.............................................................................................................. 873 Clean Outer Element....................................................................................................................... 873 Replace Element........................................................................................................................... 876 Examine Hydraulic Oil Level............................................................................................................... 876 Examine Hydraulic Oil Strainer............................................................................................................ 878 Examine Hydraulic Oil Filter.............................................................................................................. 878 Examine Oil Level in Swing Machinery Case................................................................................................. 879 Examine Oil Level in PTO Case............................................................................................................. 881 Examine PTO Lubrication Filter Strainer................................................................................................... 881 Examine Oil Level in Final Drive Case..................................................................................................... 882 Bleed Air from Fuel System................................................................................................................ 882 Bleed Air from Hydraulic System........................................................................................................... 882 How to Examine Electric Equipment......................................................................................................... 882 Preparation for Troubleshooting of Electrical System.......................................................................................... 888 Preparation for Troubleshooting of Machine Monitor........................................................................................ 888 Preparation for Troubleshooting of Engine Controller...................................................................................... 888 Preparation for Troubleshooting of Pump Controller........................................................................................ 888 Preparation for Troubleshooting of KOMTRAX Plus Controller................................................................................ 889 Preparation for Troubleshooting of KomVision Controller................................................................................... 889 How to Disconnect and Connect Connector with a Special Lock............................................................................... 889 Procedure for Troubleshooting................................................................................................................. 894 Symptom and Troubleshooting Numbers........................................................................................................... 897 Information Shown in Troubleshooting Table.................................................................................................... 902 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness............................................................... 904 Connector List and Layout..................................................................................................................... 907 Connector Contact Connection Table............................................................................................................ 930 T-Branch Box and T-Branch Adapter Table....................................................................................................... 972 Fuse Location Table........................................................................................................................... 978 Precautions When You Clean and Replace KDPF (KCSF and KDOC)................................................................................... 985 Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])................................................. 989 Failure Code Table............................................................................................................................ 991 Troubleshooting by Failure Code (Display of Code).................................................................................................1015 Failure Code [7@HAZL].........................................................................................................................1015 Failure Code [7@HBZL].........................................................................................................................1017 Failure Code [7@HCZL].........................................................................................................................1018 Failure Code [7@HDZL].........................................................................................................................1019 Failure Code [8800ZG].........................................................................................................................1020 Failure Code [989L00].........................................................................................................................1021 Failure Code [989M00].........................................................................................................................1022 Failure Code [989N00].........................................................................................................................1023 Failure Code [A1U0N3].........................................................................................................................1024 Failure Code [A1U0N4].........................................................................................................................1026 Failure Code [A900FR].........................................................................................................................1028 Failure Code [A900N6].........................................................................................................................1029 Failure Code [A900NY].........................................................................................................................1030 Failure Code [AA10NX].........................................................................................................................1031 Failure Code [AQ10N3].........................................................................................................................1032 Failure Code [B@BAZG].........................................................................................................................1033 Failure Code [B@BAZK].........................................................................................................................1034 Failure Code [B@BCNS].........................................................................................................................1035 Failure Code [B@BCQA].........................................................................................................................1036 Failure Code [B@BCZK].........................................................................................................................1038 Failure Code [B@HANS].........................................................................................................................1040 Failure Code [B@HAZK].........................................................................................................................1041 Failure Code [CA115]..........................................................................................................................1042 Failure Code [CA122]..........................................................................................................................1046 Failure Code [CA123]..........................................................................................................................1048 Failure Code [CA131]..........................................................................................................................1050 Failure Code [CA132]..........................................................................................................................1052 Failure Code [CA135]..........................................................................................................................1054 Failure Code [CA141]..........................................................................................................................1056 Failure Code [CA144]..........................................................................................................................1058 Failure Code [CA145]..........................................................................................................................1060 Failure Code [CA153]..........................................................................................................................1062 Failure Code [CA154]..........................................................................................................................1065 Failure Code [CA187]..........................................................................................................................1068 Failure Code [CA212]..........................................................................................................................1070 Failure Code [CA213]..........................................................................................................................1072 Failure Code [CA221]..........................................................................................................................1074 Failure Code [CA222]..........................................................................................................................1076 Failure Code [CA227]..........................................................................................................................1078 Failure Code [CA234]..........................................................................................................................1080 Failure Code [CA238]..........................................................................................................................1081 Failure Code [CA239]..........................................................................................................................1083 Failure Code [CA271]..........................................................................................................................1085 Failure Code [CA272]..........................................................................................................................1087 Failure Code [CA273]..........................................................................................................................1088 Failure Code [CA274]..........................................................................................................................1090 Failure Code [CA322]..........................................................................................................................1091 Failure Code [CA323]..........................................................................................................................1093 Failure Code [CA324]..........................................................................................................................1095 Failure Code [CA325]..........................................................................................................................1097 Failure Code [CA331]..........................................................................................................................1099 Failure Code [CA332]..........................................................................................................................1101 Failure Code [CA343]..........................................................................................................................1103 Failure Code [CA351]..........................................................................................................................1111 Failure Code [CA352]..........................................................................................................................1113 Failure Code [CA356]..........................................................................................................................1115 Failure Code [CA357]..........................................................................................................................1117 Failure Code [CA386]..........................................................................................................................1119 Failure Code [CA441]..........................................................................................................................1121 Failure Code [CA442]..........................................................................................................................1123 Failure Code [CA449]..........................................................................................................................1125 Failure Code [CA451]..........................................................................................................................1126 Failure Code [CA452]..........................................................................................................................1128 Failure Code [CA515]..........................................................................................................................1130 Failure Code [CA516]..........................................................................................................................1131 Failure Code [CA553]..........................................................................................................................1132 Failure Code [CA555]..........................................................................................................................1133 Failure Code [CA556]..........................................................................................................................1135 Failure Code [CA559]..........................................................................................................................1137 Failure Code [CA595]..........................................................................................................................1143 Failure Code [CA687]..........................................................................................................................1145 Failure Code [CA689]..........................................................................................................................1147 Failure Code [CA691]..........................................................................................................................1149 Failure Code [CA692]..........................................................................................................................1151 Failure Code [CA697]..........................................................................................................................1153 Failure Code [CA698]..........................................................................................................................1154 Failure Code [CA731]..........................................................................................................................1155 Failure Code [CA778]..........................................................................................................................1159 Failure Code [CA1117].........................................................................................................................1162 Failure Code [CA1135].........................................................................................................................1164 Failure Code [CA1257].........................................................................................................................1167 Failure Code [CA1664].........................................................................................................................1168 Failure Code [CA1691].........................................................................................................................1170 Failure Code [CA1695].........................................................................................................................1173 Failure Code [CA1696].........................................................................................................................1175 Failure Code [CA1843].........................................................................................................................1177 Failure Code [CA1844].........................................................................................................................1179 Failure Code [CA1879].........................................................................................................................1181 Failure Code [CA1881].........................................................................................................................1183 Failure Code [CA1883].........................................................................................................................1185 Failure Code [CA1921].........................................................................................................................1188 Failure Code [CA1922].........................................................................................................................1190 Failure Code [CA1923].........................................................................................................................1193 Failure Code [CA1924].........................................................................................................................1195 Failure Code [CA1925].........................................................................................................................1198 Failure Code [CA1927].........................................................................................................................1200 Failure Code [CA1928].........................................................................................................................1202 Failure Code [CA1942].........................................................................................................................1204 Failure Code [CA1963].........................................................................................................................1206 Failure Code [CA1977].........................................................................................................................1210 Failure Code [CA1993].........................................................................................................................1212 Failure Code [CA2185].........................................................................................................................1214 Failure Code [CA2186].........................................................................................................................1216 Failure Code [CA2249].........................................................................................................................1218 Failure Code [CA2265].........................................................................................................................1223 Failure Code [CA2266].........................................................................................................................1225 Failure Code [CA2271].........................................................................................................................1227 Failure Code [CA2272].........................................................................................................................1229 Failure Code [CA2349].........................................................................................................................1231 Failure Code [CA2353].........................................................................................................................1233 Failure Code [CA2357].........................................................................................................................1235 Failure Code [CA2381].........................................................................................................................1238 Failure Code [CA2382].........................................................................................................................1240 Failure Code [CA2383].........................................................................................................................1242 Failure Code [CA2386].........................................................................................................................1244 Failure Code [CA2387].........................................................................................................................1246 Failure Code [CA2555].........................................................................................................................1249 Failure Code [CA2556].........................................................................................................................1251 Failure Code [CA2637].........................................................................................................................1253 Failure Code [CA2639].........................................................................................................................1255 Failure Code [CA2732].........................................................................................................................1257 Failure Code [CA2733].........................................................................................................................1259 Failure Code [CA2741].........................................................................................................................1261 Failure Code [CA2765].........................................................................................................................1263 Failure Code [CA2777].........................................................................................................................1264 Failure Code [CA2878].........................................................................................................................1266 Failure Code [CA2881].........................................................................................................................1269 Failure Code [CA3133].........................................................................................................................1273 Failure Code [CA3134].........................................................................................................................1275 Failure Code [CA3135].........................................................................................................................1277 Failure Code [CA3167].........................................................................................................................1280 Failure Code [CA3251].........................................................................................................................1283 Failure Code [CA3253].........................................................................................................................1285 Failure Code [CA3254].........................................................................................................................1290 Failure Code [CA3255].........................................................................................................................1293 Failure Code [CA3256].........................................................................................................................1296 Failure Code [CA3311].........................................................................................................................1298 Failure Code [CA3312].........................................................................................................................1300 Failure Code [CA3313].........................................................................................................................1302 Failure Code [CA3314].........................................................................................................................1303 Failure Code [CA3315].........................................................................................................................1304 Failure Code [CA3316].........................................................................................................................1307 Failure Code [CA3317].........................................................................................................................1308 Failure Code [CA3318].........................................................................................................................1309 Failure Code [CA3319].........................................................................................................................1312 Failure Code [CA3321].........................................................................................................................1313 Failure Code [CA3322].........................................................................................................................1314 Failure Code [CA3419].........................................................................................................................1317 Failure Code [CA3421].........................................................................................................................1319 Failure Code [CA4151].........................................................................................................................1321 Failure Code [CA4158].........................................................................................................................1324 Failure Code [CA4161].........................................................................................................................1325 Failure Code [CA4162].........................................................................................................................1327 Failure Code [CA4163].........................................................................................................................1329 Failure Code [CA4259].........................................................................................................................1331 Failure Code [CA4952].........................................................................................................................1334 Failure Code [CA5383].........................................................................................................................1336 Failure Code [CB115]..........................................................................................................................1337 Failure Code [CB123]..........................................................................................................................1341 Failure Code [CB153]..........................................................................................................................1343 Failure Code [CB154]..........................................................................................................................1346 Failure Code [CB187]..........................................................................................................................1349 Failure Code [CB227]..........................................................................................................................1351 Failure Code [CB238]..........................................................................................................................1353 Failure Code [CB239]..........................................................................................................................1355 Failure Code [CB271]..........................................................................................................................1357 Failure Code [CB272]..........................................................................................................................1359 Failure Code [CB273]..........................................................................................................................1360 Failure Code [CB274]..........................................................................................................................1362 Failure Code [CB343]..........................................................................................................................1363 Failure Code [CB351]..........................................................................................................................1365 Failure Code [CB352]..........................................................................................................................1367 Failure Code [CB356]..........................................................................................................................1369 Failure Code [CB357]..........................................................................................................................1371 Failure Code [CB386]..........................................................................................................................1373 Failure Code [CB441]..........................................................................................................................1375 Failure Code [CB442]..........................................................................................................................1377 Failure Code [CB449]..........................................................................................................................1379 Failure Code [CB451]..........................................................................................................................1380 Failure Code [CB452]..........................................................................................................................1382 Failure Code [CB515]..........................................................................................................................1384 Failure Code [CB516]..........................................................................................................................1385 Failure Code [CB553]..........................................................................................................................1386 Failure Code [CB555]..........................................................................................................................1387 Failure Code [CB556]..........................................................................................................................1389 Failure Code [CB559]..........................................................................................................................1391 Failure Code [CB595]..........................................................................................................................1396 Failure Code [CB689]..........................................................................................................................1398 Failure Code [CB691]..........................................................................................................................1400 Failure Code [CB692]..........................................................................................................................1402 Failure Code [CB687]..........................................................................................................................1404 Failure Code [CB697]..........................................................................................................................1406 Failure Code [CB698]..........................................................................................................................1407 Failure Code [CB731]..........................................................................................................................1408 Failure Code [CB778]..........................................................................................................................1412 Failure Code [CB1117].........................................................................................................................1415 Failure Code [CB1257].........................................................................................................................1417 Failure Code [CB1548].........................................................................................................................1418 Failure Code [CB1549].........................................................................................................................1420 Failure Code [CB1551].........................................................................................................................1422 Failure Code [CB1552].........................................................................................................................1424 Failure Code [CB1553].........................................................................................................................1426 Failure Code [CB1622].........................................................................................................................1428 Failure Code [CB1664].........................................................................................................................1430 Failure Code [CB1691].........................................................................................................................1432 Failure Code [CB1695].........................................................................................................................1435 Failure Code [CB1696].........................................................................................................................1437 Failure Code [CB1843].........................................................................................................................1439 Failure Code [CB1844].........................................................................................................................1441 Failure Code [CB1879].........................................................................................................................1443 Failure Code [CB1881].........................................................................................................................1445 Failure Code [CB1883].........................................................................................................................1447 Failure Code [CB1921].........................................................................................................................1450 Failure Code [CB1922].........................................................................................................................1452 Failure Code [CB1923].........................................................................................................................1455 Failure Code [CB1924].........................................................................................................................1457 Failure Code [CB1925].........................................................................................................................1460 Failure Code [CB1927].........................................................................................................................1462 Failure Code [CB1928].........................................................................................................................1464 Failure Code [CB1942].........................................................................................................................1466 Failure Code [CB1963].........................................................................................................................1468 Failure Code [CB1977].........................................................................................................................1473 Failure Code [CB1993].........................................................................................................................1475 Failure Code [CB2249].........................................................................................................................1477 Failure Code [CB2265].........................................................................................................................1482 Failure Code [CB2266].........................................................................................................................1484 Failure Code [CB2271].........................................................................................................................1486 Failure Code [CB2272].........................................................................................................................1488 Failure Code [CB2349].........................................................................................................................1490 Failure Code [CB2353].........................................................................................................................1492 Failure Code [CB2357].........................................................................................................................1494 Failure Code [CB2381].........................................................................................................................1497 Failure Code [CB2382].........................................................................................................................1499 Failure Code [CB2383].........................................................................................................................1501 Failure Code [CB2386].........................................................................................................................1503 Failure Code [CB2387].........................................................................................................................1505 Failure Code [CB2637].........................................................................................................................1508 Failure Code [CB2639].........................................................................................................................1510 Failure Code [CB2732].........................................................................................................................1512 Failure Code [CB2733].........................................................................................................................1514 Failure Code [CB2741].........................................................................................................................1516 Failure Code [CB2765].........................................................................................................................1518 Failure Code [CB2777].........................................................................................................................1519 Failure Code [CB2878].........................................................................................................................1521 Failure Code [CB2881].........................................................................................................................1524 Failure Code [CB3313].........................................................................................................................1528 Failure Code [CB3133].........................................................................................................................1529 Failure Code [CB3134].........................................................................................................................1531 Failure Code [CB3135].........................................................................................................................1533 Failure Code [CB3167].........................................................................................................................1536 Failure Code [CB3251].........................................................................................................................1539 Failure Code [CB3253].........................................................................................................................1541 Failure Code [CB3254].........................................................................................................................1546 Failure Code [CB3255].........................................................................................................................1549 Failure Code [CB3256].........................................................................................................................1552 Failure Code [CB3311].........................................................................................................................1554 Failure Code [CB3312].........................................................................................................................1556 Failure Code [CB3313].........................................................................................................................1558 Failure Code [CB3314].........................................................................................................................1559 Failure Code [CB3315].........................................................................................................................1560 Failure Code [CB3316].........................................................................................................................1563 Failure Code [CB3317].........................................................................................................................1564 Failure Code [CB3318].........................................................................................................................1565 Failure Code [CB3319].........................................................................................................................1568 Failure Code [CB3321].........................................................................................................................1569 Failure Code [CB3322].........................................................................................................................1570 Failure Code [CB3419].........................................................................................................................1573 Failure Code [CB3421].........................................................................................................................1575 Failure Code [CB4151].........................................................................................................................1577 Failure Code [CB4158].........................................................................................................................1581 Failure Code [CB4161].........................................................................................................................1582 Failure Code [CB4162].........................................................................................................................1584 Failure Code [CB4163].........................................................................................................................1586 Failure Code [CB4259].........................................................................................................................1589 Failure Code [CB4952].........................................................................................................................1592 Failure Code [CB5383].........................................................................................................................1594 Failure Code [D110KB].........................................................................................................................1595 Failure Code [D163KB].........................................................................................................................1597 Failure Code [D195KA].........................................................................................................................1599 Failure Code [D195KB].........................................................................................................................1602 Failure Code [D19JKZ].........................................................................................................................1604 Failure Code [D1E7KA].........................................................................................................................1606 Failure Code [D1E7KB].........................................................................................................................1607 Failure Code [D1E7KY].........................................................................................................................1608 Failure Code [D1E9KB].........................................................................................................................1609 Failure Code [D1EAKB].........................................................................................................................1612 Failure Code [D1EBKB].........................................................................................................................1614 Failure Code [D1ECKB].........................................................................................................................1617 Failure Code [D1EJKA].........................................................................................................................1619 Failure Code [D1EJKB].........................................................................................................................1621 Failure Code [D1EKKA].........................................................................................................................1623 Failure Code [D1EKKB].........................................................................................................................1625 Failure Code [D1ELKA].........................................................................................................................1627 Failure Code [D1ELKB].........................................................................................................................1629 Failure Code [D1F0KA].........................................................................................................................1631 Failure Code [D1F0KB].........................................................................................................................1632 Failure Code [D1F0KY].........................................................................................................................1633 Failure Code [D8AQKR].........................................................................................................................1634 Failure Code [DA20MC].........................................................................................................................1638 Failure Code [DA22KK].........................................................................................................................1639 Failure Code [DA25KP].........................................................................................................................1642 Failure Code [DA26KP].........................................................................................................................1644 Failure Code [DA29KQ] (Backhoe Specification).................................................................................................1646 Failure Code [DA29KQ] (Loading Shovel Specification)..........................................................................................1648 Failure Code [DA2LKA].........................................................................................................................1650 Failure Code [DA2LKB].........................................................................................................................1653 Failure Code [DA2QKR].........................................................................................................................1655 Failure Code [DA2RKR].........................................................................................................................1661 Failure Code [DAF0KM].........................................................................................................................1666 Failure Code [DAF0MB].........................................................................................................................1667 Failure Code [DAF0MC].........................................................................................................................1668 Failure Code [DAF9KQ].........................................................................................................................1669 Failure Code [DAFGMC].........................................................................................................................1670 Failure Code [DAFLKA].........................................................................................................................1671 Failure Code [DAFLKB].........................................................................................................................1674 Failure Code [DAFQKR].........................................................................................................................1676 Failure Code [DB2QKR].........................................................................................................................1681 Failure Code [DB2RKR].........................................................................................................................1691 Failure Code [DBP0KM].........................................................................................................................1700 Failure Code [DBP0KT].........................................................................................................................1701 Failure Code [DBP0MC].........................................................................................................................1702 Failure Code [DBP0NR].........................................................................................................................1703 Failure Code [DBP5KP] (Applicable Machine: 30001 to 30157)....................................................................................1704 Failure Code [DBP5KP] (Applicable Machine: 30158 and up)......................................................................................1707 Failure Code [DBPLKA].........................................................................................................................1710 Failure Code [DBPLKB].........................................................................................................................1713 Failure Code [DBPQKR] (Applicable Machine: 30001 to 30157)....................................................................................1715 Failure Code [DBPQKR] (Applicable Machine: 30158 and up)......................................................................................1720 Failure Code [DBPRKR] (Applicable Machine: 30001 to 30157)....................................................................................1725 Failure Code [DBPRKR] (Applicable Machine: 30158 and up)......................................................................................1731 Failure Code [DBPUKR].........................................................................................................................1737 Failure Code [DBPVKR].........................................................................................................................1747 Failure Code [DBV0MC].........................................................................................................................1757 Failure Code [DBV1KK].........................................................................................................................1758 Failure Code [DBV5KB].........................................................................................................................1760 Failure Code [DBV6KB].........................................................................................................................1762 Failure Code [DBV8KB].........................................................................................................................1764 Failure Code [DBVLKA].........................................................................................................................1769 Failure Code [DBVLKB].........................................................................................................................1771 Failure Code [[DBVQKR]........................................................................................................................1773 Failure Code [DBVRKR].........................................................................................................................1777 Failure Code [DBVVKR].........................................................................................................................1781 Failure Code [DBVWKR].........................................................................................................................1782 Failure Code [DBWQKR].........................................................................................................................1783 Failure Code [DBWRKR].........................................................................................................................1789 Failure Code [DBX0MC].........................................................................................................................1795 Failure Code [DBX2KK].........................................................................................................................1796 Failure Code [DBX5KP].........................................................................................................................1798 Failure Code [DBX6KP].........................................................................................................................1800 Failure Code [DBX9KQ] (Backhoe Specification).................................................................................................1802 Failure Code [DBX9KQ] (Loading Shovel Specification)..........................................................................................1804 Failure Code [DBXLKA].........................................................................................................................1806 Failure Code [DBXLKB].........................................................................................................................1809 Failure Code [DBXQKR].........................................................................................................................1811 Failure Code [DBXRKR].........................................................................................................................1817 Failure Code [DBY0MC].........................................................................................................................1823 Failure Code [DBY2KK].........................................................................................................................1824 Failure Code [DBY5KP].........................................................................................................................1826 Failure Code [DBY6KP].........................................................................................................................1828 Failure Code [DBY9KQ] (Backhoe Specification).................................................................................................1830 Failure Code [DBY9KQ] (Loading Shovel Specification)..........................................................................................1832 Failure Code [DBYLKA].........................................................................................................................1834 Failure Code [DBYLKB].........................................................................................................................1837 Failure Code [DDNRKA].........................................................................................................................1839 Failure Code [DDNRKY].........................................................................................................................1841 Failure Code [DDNS00].........................................................................................................................1843 Failure Code [DDXAL4].........................................................................................................................1845 Failure Code [DGE5KB].........................................................................................................................1847 Failure Code [DGH2KA].........................................................................................................................1849 Failure Code [DGH2KB].........................................................................................................................1851 Failure Code [DGT3KB].........................................................................................................................1853 Failure Code [DGT5KA].........................................................................................................................1855 Failure Code [DGT5KB].........................................................................................................................1857 Failure Code [DGT6KA].........................................................................................................................1859 Failure Code [DGT6KB].........................................................................................................................1861 Failure Code [DH25MA].........................................................................................................................1863 Failure Code [DH26MA].........................................................................................................................1865 Failure Code [DH27MA].........................................................................................................................1867 Failure Code [DH28MA].........................................................................................................................1869 Failure Code [DHA4KA].........................................................................................................................1871 Failure Code [DHA5KA].........................................................................................................................1872 Failure Code [DHAAMA].........................................................................................................................1873 Failure Code [DHABMA].........................................................................................................................1874 Failure Code [DHACMA].........................................................................................................................1875 Failure Code [DHADMA].........................................................................................................................1876 Failure Code [DHPEMA].........................................................................................................................1877 Failure Code [DHPFMA].........................................................................................................................1879 Failure Code [DHPGMA].........................................................................................................................1881 Failure Code [DHPSMA].........................................................................................................................1883 Failure Code [DHPHMA].........................................................................................................................1885 Failure Code [DHPTMA].........................................................................................................................1887 Failure Code [DHPUMA].........................................................................................................................1889 Failure Code [DHS3MA].........................................................................................................................1891 Failure Code [DHS4MA].........................................................................................................................1894 Failure Code [DHS8MA].........................................................................................................................1897 Failure Code [DHS9MA].........................................................................................................................1900 Failure Code [DHSAMA].........................................................................................................................1903 Failure Code [DHSBMA].........................................................................................................................1906 Failure Code [DHSCMA].........................................................................................................................1909 Failure Code [DHSDMA].........................................................................................................................1912 Failure Code [DHSFMA].........................................................................................................................1915 Failure Code [DHSGMA].........................................................................................................................1918 Failure Code [DHSHMA].........................................................................................................................1921 Failure Code [DHSJMA].........................................................................................................................1924 Failure Code [DKR0MA].........................................................................................................................1927 Failure Code [DKR1MA].........................................................................................................................1930 Failure Code [DKR2KA].........................................................................................................................1933 Failure Code [DKR2KB].........................................................................................................................1934 Failure Code [DKR2NX].........................................................................................................................1935 Failure Code [DKR3KA].........................................................................................................................1937 Failure Code [DKR3KB].........................................................................................................................1938 Failure Code [DKR3NX].........................................................................................................................1939 Failure Code [DKR4KA].........................................................................................................................1941 Failure Code [DKR4KB].........................................................................................................................1942 Failure Code [DKR4NX].........................................................................................................................1943 Failure Code [DKR5MA].........................................................................................................................1945 Failure Code [DKR6MA].........................................................................................................................1948 Failure Code [[DKTKKX]........................................................................................................................1951 Failure Code [DKULKA].........................................................................................................................1953 Failure Code [DKULKB].........................................................................................................................1955 Failure Code [DKULKY].........................................................................................................................1957 Failure Code [DKVEL8].........................................................................................................................1959 Failure Code [DKVEMA].........................................................................................................................1961 Failure Code [DKVFL8].........................................................................................................................1963 Failure Code [DKVFMA].........................................................................................................................1965 Failure Code [DKVGL8].........................................................................................................................1967 Failure Code [DKVGMA].........................................................................................................................1969 Failure Code [DKVHL8].........................................................................................................................1971 Failure Code [DKVHMA].........................................................................................................................1973 Failure Code [DKVJL8].........................................................................................................................1975 Failure Code [DKVJMA].........................................................................................................................1977 Failure Code [DLM3KA].........................................................................................................................1979 Failure Code [DLM3KB].........................................................................................................................1981 Failure Code [DLM3MB].........................................................................................................................1983 Failure Code [DLM8KA].........................................................................................................................1987 Failure Code [DLM8KB].........................................................................................................................1988 Failure Code [DLM8MB].........................................................................................................................1989 Failure Code [DMU6KB].........................................................................................................................1990 Failure Code [DMU6KB].........................................................................................................................1992 Failure Code [DMU6KB].........................................................................................................................1994 Failure Code [DPQ1LD].........................................................................................................................1996 Failure Code [DPQ4KB].........................................................................................................................1997 Failure Code [DPQ4KT].........................................................................................................................1998 Failure Code [DR10KA].........................................................................................................................1999 Failure Code [DR20KA].........................................................................................................................2001 Failure Code [DR21KX].........................................................................................................................2003 Failure Code [DR30KA].........................................................................................................................2005 Failure Code [DR40KA].........................................................................................................................2007 Failure Code [DR50KA].........................................................................................................................2009 Failure Code [DR60KA].........................................................................................................................2011 Failure Code [DR90KA].........................................................................................................................2013 Failure Code [DV20KB].........................................................................................................................2015 Failure Code [DW45KA].........................................................................................................................2017 Failure Code [DW45KB].........................................................................................................................2020 Failure Code [DW45KY].........................................................................................................................2023 Failure Code [DW7BKA].........................................................................................................................2025 Failure Code [DW7BKB].........................................................................................................................2027 Failure Code [DW7BKY].........................................................................................................................2029 Failure Code [DW7HKA].........................................................................................................................2030 Failure Code [DW7HKB].........................................................................................................................2032 Failure Code [DW7HKY].........................................................................................................................2034 Failure Code [DWA5KA].........................................................................................................................2036 Failure Code [DWA5KB].........................................................................................................................2038 Failure Code [DWA5KY].........................................................................................................................2040 Failure Code [DWACKA].........................................................................................................................2041 Failure Code [DWACKB].........................................................................................................................2043 Failure Code [DWACKY].........................................................................................................................2045 Failure Code [DWK0KA].........................................................................................................................2046 Failure Code [DWK0KB].........................................................................................................................2048 Failure Code [DWK0KY].........................................................................................................................2050 Failure Code [DWK2KA].........................................................................................................................2052 Failure Code [DWK2KB].........................................................................................................................2054 Failure Code [DWK2KY].........................................................................................................................2056 Failure Code [DWM1KA].........................................................................................................................2058 Failure Code [DWM1KB].........................................................................................................................2060 Failure Code [DWM1KY].........................................................................................................................2062 Failure Code [DWN5KA].........................................................................................................................2064 Failure Code [DWN5KB].........................................................................................................................2065 Failure Code [DWNCKA].........................................................................................................................2066 Failure Code [DWNCKB].........................................................................................................................2067 Failure Code [DWNPKA].........................................................................................................................2068 Failure Code [DWNPKB].........................................................................................................................2070 Failure Code [DWNPKY].........................................................................................................................2072 Failure Code [DWNQKA].........................................................................................................................2073 Failure Code [DWNQKB].........................................................................................................................2075 Failure Code [DWNQKY].........................................................................................................................2077 Failure Code [DWNRKA].........................................................................................................................2078 Failure Code [DWNRKB].........................................................................................................................2080 Failure Code [DWNRKY].........................................................................................................................2082 Failure Code [DXR9KY].........................................................................................................................2084 Failure Code [DXAAKA].........................................................................................................................2085 Failure Code [DXAAKB].........................................................................................................................2087 Failure Code [DXABKA].........................................................................................................................2089 Failure Code [DXABKB].........................................................................................................................2091 Failure Code [DXACKA].........................................................................................................................2093 Failure Code [DXACKB].........................................................................................................................2095 Failure Code [DXADKA].........................................................................................................................2097 Failure Code [DXADKB].........................................................................................................................2099 Failure Code [DXR6KA].........................................................................................................................2101 Failure Code [DXR6KB].........................................................................................................................2102 Failure Code [DXR6KY].........................................................................................................................2103 Failure Code [DXR9KA].........................................................................................................................2104 Failure Code [DXR9KB].........................................................................................................................2105 Failure Code [DXR9KY].........................................................................................................................2106 Failure Code [DXRAKA].........................................................................................................................2107 Failure Code [DXRAKB].........................................................................................................................2108 Failure Code [DXRAKY].........................................................................................................................2109 Failure Code [DXRCKA].........................................................................................................................2110 Failure Code [DXRCKB].........................................................................................................................2111 Failure Code [DXRCKY].........................................................................................................................2112 Failure Code [DXRDKA].........................................................................................................................2113 Failure Code [DXRDKB].........................................................................................................................2114 Failure Code [DXRDKY].........................................................................................................................2115 Failure Code [DXRFKA].........................................................................................................................2116 Failure Code [DXRFKB].........................................................................................................................2117 Failure Code [DXRFKY].........................................................................................................................2118 Failure Code [DXRJKA].........................................................................................................................2119 Failure Code [DXRJKB].........................................................................................................................2120 Failure Code [DXRJKY].........................................................................................................................2121 Failure Code [DY20MA].........................................................................................................................2122 Failure Code [DY2CKA].........................................................................................................................2125 Failure Code [DY2CKY].........................................................................................................................2127 Failure Code [DY2FMA].........................................................................................................................2129 Failure Code [F@BYNR].........................................................................................................................2132 Failure Code [F@BYNS].........................................................................................................................2133 Failure Code [F@BZNR].........................................................................................................................2134 Failure Code [F@BZNS].........................................................................................................................2135 Failure Code [F7FQKR].........................................................................................................................2136 Failure Code [F7G0MC].........................................................................................................................2138 Failure Code [LA10ZL].........................................................................................................................2139 Failure Code [LA20ZL].........................................................................................................................2140 Troubleshooting of Electrical System (E-Mode).....................................................................................................2141 E-1 Engine Does Not Start (Engine Does Not Crank).............................................................................................2141 E-2 Manual Preheating System Does Not Operate.................................................................................................2150 E-3 Automatic Preheating System Does Not Operate..............................................................................................2153 E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On.....................................................................2155 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing..............................................................2157 E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow.........................2160 E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow...................2161 E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation..................................................................2162 E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs.....................................................................2163 E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs........................................................................2164 E-11 Charge Level Monitor Comes On in Red While Engine is in Operation........................................................................2165 E-12 Fuel Level Monitor Comes On in Red While Engine Runs.....................................................................................2166 E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation..........................................................2167 E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation.................................................................2168 E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation...........................................................2169 E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum.................................................................................2170 E-17 Display of Fuel Gauge is Different from Actual Fuel Level................................................................................2172 E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum..................................................................2173 E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature........................................................2174 E-20 Some Areas of Machine Monitor Screen are Not Shown.......................................................................................2175 E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum............................................................2176 E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature......................................................2178 E-23 Function Switch Does Not Operate.........................................................................................................2179 E-24 Automatic Warm-up System Does Not Work (in Cold Weather).................................................................................2180 E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out...................................2181 E-26 Auto-Decelerator is Not Operated or Canceled with Lever..................................................................................2182 E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown.........................................................2183 E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed........................................................2184 E-29 Service Meter is Not Shown, While Starting Switch is in OFF Position.....................................................................2185 E-30 Service Mode Cannot be Selected..........................................................................................................2186 E-31 All of Work Equipment, Swing, and Travel Mechanism Do Not Move...........................................................................2187 E-32 All Work Equipment, Swing and Travel Do Not Lock.........................................................................................2190 E-33 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing...........................................................2192 E-34 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate...........................................2194 E-35 Horn Does Not Sound......................................................................................................................2196 E-36 Horn Does Not Stop.......................................................................................................................2199 E-37 Alarm Does Not Sound During Travel.......................................................................................................2201 E-38 Alarm Does Not Stop When Machine Stops...................................................................................................2203 E-39 Alarm Buzzer Cannot be Canceled..........................................................................................................2204 E-40 Room Lamp, Headlamp, and Working Lamp Do Not Come On.....................................................................................2205 E-41 Headlamp or Working Lamp Does Not Come On................................................................................................2208 E-42 Room Lamp Does Not Come On...............................................................................................................2212 E-43 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out..................................................................2214 E-44 Wiper Does Not Operate When Wiper Switch is Operated (Upper Wiper Specification).........................................................2215 E-45 Wiper Does Not Operate When Wiper Switch is Operated (Lower Wiper Specification).........................................................2218 E-46 Fuel Feed Pump Does Not Operate or Stop Automatically....................................................................................2221 E-47 Window Washer Does Not Operate When Window Washer Switch is Operated.....................................................................2225 E-48 "Arm OUT" is Not Shown Correctly with Monitoring Function................................................................................2226 E-49 "Arm IN" is Not Shown Correctly with Monitoring Function.................................................................................2227 E-50 "Bucket DUMP" is Not Shown Correctly with Monitoring Function............................................................................2228 E-51 "Bucket CURL" is Not Shown Correctly with Monitoring Function............................................................................2229 E-52 "Swing" is Not Shown Correctly with Monitoring Function..................................................................................2230 E-53 "Travel” is Not Shown Correctly with Monitoring Function.................................................................................2231 E-54 "Boom RAISE" is Not Shown Correctly with Monitoring Function.............................................................................2232 E-55 "Boom LOWER" is Not Shown Correctly with Monitoring Function.............................................................................2233 E-56 KOMTRAX System Does Not Operate Correctly................................................................................................2234 E-57 Machine Push-Up Function is Not Canceled.................................................................................................2235 E-58 Machine Push-up Function Does Not Operate................................................................................................2237 E-59 Step Light Does Not Come On..............................................................................................................2238 E-60 Step Light Does Not Go Out...............................................................................................................2241 E-61 Boom Shockless Function Cannot be Canceled...............................................................................................2243 E-62 Boom Shockless Function Does Not Work....................................................................................................2245 E-63 Air Conditioner Control Panel Does Not Turn on...........................................................................................2246 E-64 Wind Does Not Come Out from the Air Conditioner..........................................................................................2248 E-65 Air Conditioner is Weak in Cold (Electric Capacitor Does Not Move or Only Hi Rotation Moves).............................................2250 E-66 Air Conditioner Does Not Get Cold (Compressor Does Not Move).............................................................................2252 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).....................................................................................2255 H-1 All Work Equipment, Swing and Travel Do Not Work..........................................................................................2255 H-2 All Work Equipment, Travel, Swing Speed or Power is Low...................................................................................2256 H-3 Engine Speed Drops Significantly or Engine Stalls.........................................................................................2258 H-4 Unusual Noise is Heard from Around Work Equipment Pump....................................................................................2259 H-5 Boom Speed or Power is Low in Normal Mode.................................................................................................2260 H-6 Boom RAISE Speed or Power is Low in Heavy Lift Mode.......................................................................................2261 H-7 Boom LOWER Speed or Power is Low in Machine Push Up Mode..................................................................................2262 H-8 Arm Speed or Power is Low.................................................................................................................2263 H-9 Bucket Speed or Power is Low..............................................................................................................2264 H-10 Boom Does Not Operate....................................................................................................................2265 H-11 Arm Does Not Operate.....................................................................................................................2266 H-12 Bucket Does Not Operate..................................................................................................................2267 H-13 Hydraulic Drift of Boom is Large.........................................................................................................2268 H-14 Hydraulic Drift of Arm is Large..........................................................................................................2269 H-15 Hydraulic Drift of Bucket is Large.......................................................................................................2270 H-16 Time Lag of Boom is Large................................................................................................................2271 H-17 Time Lag of Arm is Large.................................................................................................................2272 H-18 Time Lag of Bucket is Large..............................................................................................................2273 H-19 Boom Shockless Function Does Not Work or Cannot be Released..............................................................................2274 H-20 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Same Direction When Traveling Forward and Reverse)..........2275 H-21 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Different Directions When Traveling Forward and Reverse)....2277 H-22 Travel Deviation is Large at Start of Travel Only When Travel Lever is Fully Moved.......................................................2278 H-23 Regardless of the Stroke of the Travel Lever, Travel Deviation is Large at Start of Traveling............................................2279 H-24 Travel Deviation is Large at Mixed Operation.............................................................................................2280 H-25 Travel Speed or Power is Low.............................................................................................................2281 H-26 Only the One Side Track Can Operate (Machine Does Not Travel FORWARD or REVERSE).........................................................2282 H-27 Only the One Side Track Can Operate (in Either Forward or Reverse Direction).............................................................2283 H-28 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast........................................................................2284 H-29 Upper Structure Does Not Swing to Right and Left.........................................................................................2285 H-30 Upper Structure Swings Only to Right or Left.............................................................................................2286 H-31 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left)..........................................................2287 H-32 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction............................................2288 H-33 In Mixed Operation of Work Equipment, Swing Speed or Power is Low........................................................................2289 H-34 While Mixed Operation with Boom Swing Speed is Low or Swing Acceleration Performance is Unsatisfactory...................................2290 H-35 Upper Structure Overruns Too Much When It Stops Swing Operation in Lateral Directions of Right and Left..................................2291 H-36 Upper Structure Speed is High When It Stops Swing Operation (on One Side)................................................................2292 H-37 Shock is Large When Upper Structure Stops Swing Operation (Right and Left)...............................................................2293 H-38 Shock is Large When Upper Structure Stops Swing Operation (in Only Right of Left Direction)..............................................2294 H-39 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation (in Right and Left Directions)...................................2295 H-40 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation in Only One Direction............................................2296 H-41 Swing Drift on a Slope is Large..........................................................................................................2297 H-42 Fan Rotation is Abnormal (Such as Excessive Noise or Vibration of Fan, or Overheating)...................................................2298 H-43 Bottom Dump Speed is Low or Power is Low (Loading Shovel Specifications).................................................................2299 H-44 Bottom Dump Cylinder Dose Not Move (Loading Shovel Specifications).......................................................................2300 Troubleshooting of Engine (S-Mode)................................................................................................................2301 Information Shown in Troubleshooting Table (S-Mode)...........................................................................................2301 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position....................................................................2302 S-2 Engine Cranks but No Exhaust Smoke Comes Out..............................................................................................2303 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)..................................................2304 S-4 Engine Startability is Unsatisfactory.....................................................................................................2305 S-5 Engine Does Not Pick Up Smoothly..........................................................................................................2307 S-6 Engine Stops During Operation.............................................................................................................2309 S-7 Engine Runs Rough or is Not Stable........................................................................................................2311 S-8 Engine Lacks Power........................................................................................................................2312 S-9 KDPF Becomes Clogged in a Short Time......................................................................................................2314 S-10 Engine Oil Consumption is Excessive......................................................................................................2316 S-11 Oil Becomes Dirty Quickly................................................................................................................2317 S-12 Fuel Consumption is Excessive............................................................................................................2318 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant.....................................................................................2319 S-14 Oil Pressure Drops.......................................................................................................................2320 S-15 Fuel Mixes Into Engine Oil...............................................................................................................2322 S-16 Water Mixes Into Engine Oil (Milky)......................................................................................................2323 S-17 Coolant Temperature Increases Too High (Overheating).....................................................................................2324 S-18 Unusual Noise is Heard...................................................................................................................2326 S-19 Vibration is Excessive...................................................................................................................2327 S-20 Air Cannot be Bled from Fuel Circuit.....................................................................................................2328 S-21 Active Regeneration is Done Frequently...................................................................................................2329 S-22 Active Regeneration Continues Long.......................................................................................................2330 S-23 White Smoke is Exhausted During Active Regeneration......................................................................................2331 50 Disassembly and Assembly...........................................................................................................................2333 Table of Contents.................................................................................................................................2334 Precautions Before Work...........................................................................................................................2340 Related Information on Disassembly and Assembly...................................................................................................2341 How to Read This Manual.......................................................................................................................2341 Coating Materials List........................................................................................................................2343 Special Tool List.............................................................................................................................2348 Sketches of Special Tools.....................................................................................................................2366 Engine and Cooling System.........................................................................................................................2369 Remove and Install Supply Pump Assembly (Right Bank)..........................................................................................2369 How to Remove Supply Pump Assembly (Right Bank)...........................................................................................2369 How to Install Supply Pump Assembly (Right Bank)..........................................................................................2382 Remove and Install Supply Pump Assembly (Left Bank)...........................................................................................2404 How to Remove Supply Pump Assembly (Left Bank)............................................................................................2404 How to Install Supply Pump Assembly (Left Bank)...........................................................................................2413 Remove and Install Injector Assembly (Right Bank).............................................................................................2427 How to Remove Injector Assembly (Right Bank)..............................................................................................2427 How to Install Injector Assembly (Right Bank).............................................................................................2440 Remove and Install Injector Assembly (Left Bank)..............................................................................................2458 How to Remove Injector Assembly (Left Bank)...............................................................................................2458 How to Install Injector Assembly (Left Bank)..............................................................................................2472 Remove and Install Fuel Doser Assembly (Right Bank)...........................................................................................2491 How to Remove Fuel Doser Assembly (Right Bank)............................................................................................2491 How to Install Fuel Doser Assembly (Right Bank)...........................................................................................2494 Remove and Install Fuel Doser Assembly (Left Bank)............................................................................................2498 How to Remove Fuel Doser Assembly (Left Bank).............................................................................................2498 How to Install Fuel Doser Assembly (Left Bank)............................................................................................2501 Remove and Install Cylinder Head Assembly (Right Bank)........................................................................................2505 How to Remove Cylinder Head Assembly (Right Bank).........................................................................................2505 How to Install Cylinder Head Assembly (Right Bank)........................................................................................2539 Remove and Install Cylinder Head Assembly (Left Bank).........................................................................................2588 How to Remove Cylinder Head Assembly (Left Bank)..........................................................................................2588 How to Install Cylinder Head Assembly (Left Bank).........................................................................................2628 Remove and Install EGR Valve Assembly (Right Bank)............................................................................................2688 How to Remove EGR Valve Assembly (Right Bank).............................................................................................2688 How to Install EGR Valve Assembly (Right Bank)............................................................................................2700 Remove and Install EGR Valve Assembly (Left Bank).............................................................................................2716 How to Remove EGR Valve Assembly (Left Bank)..............................................................................................2716 How to Install EGR Valve Assembly (Left Bank).............................................................................................2728 Remove and Install EGR Cooler Assembly (Right Bank)...........................................................................................2746 How to Remove EGR Cooler Assembly (Right Bank)............................................................................................2746 How to Install EGR Cooler Assembly (Right Bank)...........................................................................................2767 Remove and Install EGR Cooler Assembly (Left Bank)............................................................................................2796 How to Remove EGR Cooler Assembly (Left Bank).............................................................................................2796 How to Install EGR Cooler Assembly (Left Bank)............................................................................................2814 Remove and Install Starter Assembly...........................................................................................................2840 How to Remove Starting Motor Assembly.....................................................................................................2840 How to Install Starting Motor Assembly....................................................................................................2843 Remove and Install Alternator Belt............................................................................................................2846 How to Remove Alternator Belt.............................................................................................................2846 How to Install Alternator Belt............................................................................................................2848 Remove and Install Alternator Assembly........................................................................................................2852 How to Remove Alternator Assembly.........................................................................................................2852 How to Install Alternator Assembly........................................................................................................2855 Remove and Install Radiator Assembly..........................................................................................................2861 How to Remove Radiator Assembly...........................................................................................................2861 How to Install Radiator Assembly..........................................................................................................2866 Remove and Install Hydraulic Oil Cooler Assembly..............................................................................................2872 How to Remove Hydraulic Oil Cooler Assembly...............................................................................................2872 How to Install Hydraulic Oil Cooler Assembly..............................................................................................2875 Remove and Install Aftercooler Assembly.......................................................................................................2879 How to Remove Aftercooler Assembly........................................................................................................2879 How to Install Aftercooler Assembly.......................................................................................................2884 Remove and Install Cooling Fan Motor Assembly.................................................................................................2890 How to Remove Cooling Fan Motor Assembly..................................................................................................2890 How to Install Cooling Fan Motor Assembly.................................................................................................2916 Remove and Install Power Module Packaging Assembly............................................................................................2941 How to Remove Power Module Packaging Assembly.............................................................................................2941 How to Install Power Module Packaging Assembly............................................................................................2956 Remove and Install Engine, PTO, and Hydraulic Pump Assembly...................................................................................2971 How to Remove Engine PTO and Hydraulic Assembly...........................................................................................2972 How to Install Engine PTO and Hydraulic Assembly..........................................................................................3004 Remove and Install Engine Front Oil Seal......................................................................................................3037 How to Remove Engine Front Oil Seal.......................................................................................................3037 How to Install Engine Front Oil Seal......................................................................................................3044 Remove and Install Engine Rear Oil Seal.......................................................................................................3052 How to Remove Engine Rear Oil Seal........................................................................................................3052 How to Install Engine Rear Oil Seal.......................................................................................................3054 Remove and Install Fuel Cooler Assembly.......................................................................................................3058 How to Remove Fuel Cooler Assembly........................................................................................................3058 How to Install Fuel Cooler Assembly.......................................................................................................3060 Remove and Install Engine Hood Assembly.......................................................................................................3062 How to Remove Engine Hood Assembly........................................................................................................3062 How to Install Engine Hood Assembly.......................................................................................................3067 Remove and Install Fuel Tank Assembly.........................................................................................................3073 How to Remove Fuel Tank Assembly..........................................................................................................3073 How to Install Fuel Tank Assembly.........................................................................................................3076 Remove and Install KDPF Assembly..............................................................................................................3080 How to Remove KDPF Assembly...............................................................................................................3080 How to Install KDPF Assembly..............................................................................................................3089 Remove and Install Bellows Pipe Assembly......................................................................................................3100 How to Remove Bellows Pipe Assembly.......................................................................................................3100 How to Install Bellows Pipe Assembly......................................................................................................3102 Remove and Install KCCV Assembly (Right Bank).................................................................................................3103 How to Remove KCCV Assembly (Right Bank)..................................................................................................3103 How to Install KCCV Assembly (Right Bank).................................................................................................3106 Remove and Install KCCV Assembly (Left Bank)..................................................................................................3110 How to Remove KCCV Assembly (Left Bank)...................................................................................................3110 How to Install KCCV Assembly (Left Bank)..................................................................................................3113 Remove and Install VGT Assembly (Right Bank)..................................................................................................3119 How to Remove VGT Assembly (Right Bank)...................................................................................................3119 How to Install VGT Assembly (Right Bank)..................................................................................................3133 Remove and Install VGT Assembly (Left Bank)...................................................................................................3149 How to Remove VGT Assembly (Left Bank)....................................................................................................3149 How to Install VGT Assembly (Left Bank)...................................................................................................3163 Remove and Install Air Cleaner Assembly.......................................................................................................3179 How to Remove Air Cleaner Assembly........................................................................................................3179 How to Install Air Cleaner Assembly.......................................................................................................3182 Remove and Install Air Conditioner Compressor Assembly........................................................................................3186 How to Remove Air Conditioner Compressor Assembly.........................................................................................3186 How to Install Air Conditioner Compressor Assembly........................................................................................3188 Remove and Install Air Conditioner Condenser Assembly.........................................................................................3192 How to Remove Air Conditioner Condenser Assembly..........................................................................................3192 How to Install Air Conditioner Condenser Assembly.........................................................................................3194 Power Train.......................................................................................................................................3198 Disassemble and Assemble PTO Assembly.........................................................................................................3198 How to Disassemble PTO Assembly...........................................................................................................3198 How to Assemble PTO Assembly..............................................................................................................3203 Remove and Install PTO Assembly...............................................................................................................3207 How to Remove PTO Assembly................................................................................................................3207 How to Install PTO Assembly...............................................................................................................3208 Remove and Install Travel Motor and Final Drive Assembly......................................................................................3209 How to Remove Travel Motor and Final Drive Assembly.......................................................................................3209 How to Install Travel Motor and Final Drive Assembly......................................................................................3213 Disassemble and Assemble Final Drive Assembly.................................................................................................3217 How to Disassemble Final Drive Assembly...................................................................................................3218 How to Assemble Final Drive Assembly......................................................................................................3224 Remove and Install Swing Motor and Swing Machinery Assembly...................................................................................3233 How to Remove Swing Motor and Swing Machinery Assembly....................................................................................3234 How to Install Swing Motor and Swing Machinery Assembly...................................................................................3241 Disassemble and Assemble Swing Machinery Assembly.............................................................................................3248 How to Disassemble Swing Machinery Assembly...............................................................................................3248 How to Assemble Swing Machinery Assembly..................................................................................................3254 Remove and Install Swing Circle Assembly......................................................................................................3261 How to Remove Swing Circle Assembly.......................................................................................................3261 How to Install Swing Circle Assembly......................................................................................................3261 Undercarriage and Frame...........................................................................................................................3263 Remove and Install Idler Assembly.............................................................................................................3263 How to Remove Idler Assembly..............................................................................................................3263 How to Install Idler Assembly.............................................................................................................3264 Remove and Install Track Roller Assembly......................................................................................................3265 How to Remove Track Roller Assembly.......................................................................................................3265 How to Install Track Roller Assembly......................................................................................................3266 Remove and Install Carrier Roller Assembly....................................................................................................3268 How to Remove Carrier Roller Assembly.....................................................................................................3268 How to Install Carrier Roller Assembly....................................................................................................3269 Separate and Connect Track Assembly...........................................................................................................3271 How to Separate Track Assembly............................................................................................................3271 How to Install Track Assembly.............................................................................................................3272 Disassemble and Assemble Idler Assembly.......................................................................................................3274 How to Disassemble Idler Assembly.........................................................................................................3274 How to Assemble Idler Assembly............................................................................................................3276 Disassemble and Assemble Idler Adjustment Cylinder Assembly...................................................................................3279 How to Disassemble Idler Adjustment Cylinder Assembly.....................................................................................3279 How to Assemble Idler Adjustment Cylinder Assembly........................................................................................3280 Disassemble and Assemble Track Roller Assembly................................................................................................3282 How to Disassemble Track Roller Assembly..................................................................................................3282 How to Assemble Track Roller Assembly.....................................................................................................3283 Disassemble and Assemble Carrier Roller Assembly..............................................................................................3285 How to Disassemble Carrier Roller Assembly................................................................................................3285 How to Assemble Carrier Roller Assembly...................................................................................................3286 Remove and Install Revolving Frame Assembly...................................................................................................3289 How to Remove Revolving Frame Assembly....................................................................................................3289 How to Install Revolving Frame Assembly...................................................................................................3293 Remove and Install Counterweight Assembly.....................................................................................................3297 How to Remove Counterweight Assembly......................................................................................................3297 How to Install Counterweight Assembly.....................................................................................................3299 Hydraulic System..................................................................................................................................3302 Remove and Install Center Swivel Joint Assembly...............................................................................................3302 How to Remove Center Swivel Joint Assembly................................................................................................3302 How to Install Center Swivel Joint Assembly...............................................................................................3304 Disassemble and Assemble Center Swivel Joint Assembly.........................................................................................3308 How to Disassemble Center Swivel Joint Assembly...........................................................................................3309 How to Assemble Center Swivel Joint Assembly..............................................................................................3310 Remove and Install Hydraulic Tank Assembly....................................................................................................3311 How to Remove Hydraulic Tank Assembly.....................................................................................................3311 How to Install Hydraulic Tank Assembly....................................................................................................3319 Remove and Install Hydraulic Pump Assembly....................................................................................................3327 How to Remove Hydraulic Pump Assembly.....................................................................................................3328 How to Install Hydraulic Pump Assembly....................................................................................................3346 Remove and Install Control Valve Assembly.....................................................................................................3365 How to Remove Control Valve Assembly......................................................................................................3366 How to Install Control Valve Assembly.....................................................................................................3379 Remove and Install Swing Motor Assembly.......................................................................................................3395 How to Remove Swing Motor Assembly........................................................................................................3395 How to Install Swing Motor Assembly.......................................................................................................3401 Disassemble and Assemble Work Equipment PPC Valve Assembly....................................................................................3407 How to Disassemble Work Equipment PPC Valve Assembly......................................................................................3407 How to Assemble Work Equipment PPC Valve Assembly.........................................................................................3407 Disassemble and Assemble Travel PPC Valve Assembly............................................................................................3410 How to Disassemble Travel PPC Valve Assembly..............................................................................................3410 How to Assemble Travel PPC Valve Assembly.................................................................................................3411 Disassemble and Assemble Grease Gun Assembly..................................................................................................3414 How to Disassemble Grease Gun Assembly....................................................................................................3414 How to Assemble Grease Gun Assembly.......................................................................................................3414 Work Equipment....................................................................................................................................3415 Remove and Install Bucket Cylinder Assembly (Backhoe Specification)...........................................................................3415 How to Remove Bucket Cylinder Assembly (Backhoe Specification)............................................................................3415 How to Install Bucket Cylinder Assembly (Backhoe Specification)...........................................................................3417 Remove and Install Bucket Cylinder Assembly (Loading Shovel Specification)....................................................................3420 How to Remove Bucket Cylinder Assembly (Loading Shovel Specification).....................................................................3420 How to Install Bucket Cylinder Assembly (Loading Shovel Specification)....................................................................3421 Remove and Install Arm Cylinder Assembly (Backhoe Specification)..............................................................................3423 How to Remove Arm Cylinder Assembly (Backhoe Specification)...............................................................................3423 How to Install Arm Cylinder Assembly (Backhoe Specification)..............................................................................3425 Remove and Install Arm Cylinder Assembly (Loading Shovel Specification).......................................................................3428 How to Remove Arm Cylinder Assembly (Loading Shovel Specification)........................................................................3428 How to Install Arm Cylinder Assembly (Loading Shovel Specification).......................................................................3429 Remove and Install Boom Cylinder Assembly (Backhoe Specification).............................................................................3430 How to Remove Boom Cylinder Assembly (Backhoe Specification)..............................................................................3430 How to Install Boom Cylinder Assembly (Backhoe Specification).............................................................................3433 Remove and Install Boom Cylinder Assembly (Loading Shovel Specification)......................................................................3436 How to Remove Boom Cylinder Assembly (Loading Shovel Specification).......................................................................3436 How to Install Boom Cylinder Assembly (Loading Shovel Specification)......................................................................3437 Remove and Install Bucket Assembly (Backhoe Specification)....................................................................................3439 How to Remove Bucket Assembly (Backhoe Specification).....................................................................................3439 How to Install Bucket Assembly (Backhoe Specification)....................................................................................3441 Remove and Install Bucket Assembly (Loading Shovel Specification).............................................................................3444 How to Remove Bucket Assembly (Loading Shovel Specification)..............................................................................3444 How to Install Bucket Assembly (Loading Shovel Specification).............................................................................3445 Remove and Install Arm Assembly (Backhoe Specification).......................................................................................3448 How to Remove Arm Assembly (Backhoe Specification)........................................................................................3448 How to Install Arm Assembly (Backhoe Specification).......................................................................................3454 Remove and Install Arm Assembly (Loading Shovel Specification)................................................................................3459 How to Remove Arm Assembly (Loading Shovel Specification).................................................................................3459 How to Install Arm Assembly (Loading Shovel Specification)................................................................................3460 Remove and Install Boom Assembly (Backhoe Specification)......................................................................................3462 How to Remove Boom Assembly (Backhoe Specification).......................................................................................3462 How to Install Boom Assembly (Backhoe Specification)......................................................................................3465 Remove and Install Boom Assembly (Loading Shovel Specification)...............................................................................3469 How to Remove Boom Assembly (Loading Shovel Specification)................................................................................3469 How to Install Boom Assembly (Loading Shovel Specification)...............................................................................3471 Disassemble and Assemble Work Equipment Cylinder Assembly (Backhoe Specification).............................................................3474 How to Disassemble Work Equipment Cylinder Assembly (Backhoe Specification)...............................................................3475 How to Assemble Work Equipment Cylinder Assembly (Backhoe Specification)..................................................................3478 Remove and Install Bottom Dump Cylinder Assembly (Loading Shovel Specification)...............................................................3483 How to Remove Bottom Dump Cylinder Assembly (Loading Shovel Specification)................................................................3483 How to Install Bottom Dump Cylinder Assembly (Loading Shovel Specification)...............................................................3484 CAB Related Parts.................................................................................................................................3486 Remove and Install Operator Cab Assembly......................................................................................................3486 How to Remove Operator Cab Assembly.......................................................................................................3487 How to Install Operator Cab Assembly......................................................................................................3494 Remove and Install CAB Base...................................................................................................................3501 How to Remove Cab Base....................................................................................................................3501 How to Install Cab Base...................................................................................................................3505 Remove and Install Operator Cab Glass (Adhered Glass).........................................................................................3510 How to Remove Operator Cab Glass (Adhered Glass)..........................................................................................3511 How to Install Operator Cab Glass (Adhered Glass).........................................................................................3512 Remove and Install Operator Cab Glass (Assembling Type).......................................................................................3519 How to Remove Operator Cab Glass (Assembling Type)........................................................................................3519 How to Install Operator Cab Glass (Assembling Type).......................................................................................3521 Remove and Install Air Conditioner Unit Assembly..............................................................................................3523 How to Remove Air Conditioner Unit Assembly...............................................................................................3523 How to Install Air Conditioner Unit Assembly..............................................................................................3538 Remove and Install Operator Seat..............................................................................................................3551 How to Remove Operator Seat...............................................................................................................3551 How to Install Operator Seat..............................................................................................................3554 How to Remove and Install Seat Belt...........................................................................................................3557 How to Remove Seat Belt...................................................................................................................3557 How to Install Seatbelt...................................................................................................................3558 Remove and Install Work Equipment Control Lever Assembly......................................................................................3560 How to Remove Work Equipment Control Lever Assembly.......................................................................................3560 How to Install Work Equipment Control Lever Assembly......................................................................................3564 Remove and Install Front Wiper Assembly.......................................................................................................3570 How to Remove Front Wiper Assembly........................................................................................................3570 How to Install Front Wiper Assembly.......................................................................................................3574 Electrical System.................................................................................................................................3578 Remove and Install Engine Controller Assembly (Right Bank)....................................................................................3578 How to Remove Engine Controller Assembly (Right Bank).....................................................................................3578 How to Install Engine Controller Assembly (Right Bank)....................................................................................3579 Remove and Install Engine Controller Assembly (Left Bank).....................................................................................3582 How to Remove Engine Controller Assembly (Left Bank)......................................................................................3582 How to Install Engine Controller Assembly (Left Bank).....................................................................................3583 Remove and Install Pump Controller Assembly...................................................................................................3586 How to Remove Pump Controller Assembly....................................................................................................3586 How to Install Pump Controller Assembly...................................................................................................3587 Remove and Install KomVision Controller Assembly..............................................................................................3589 How to Remove KomVision Controller Assembly...............................................................................................3589 How to Install KomVision Controller Assembly..............................................................................................3590 Remove and Install Machine Monitor Assembly...................................................................................................3592 How to Remove Machine Monitor Assembly....................................................................................................3592 How to Install Machine Monitor Assembly...................................................................................................3595 Remove and Install Mass Air Flow and Temperature Sensor.......................................................................................3598 How to Remove Mass Air Flow and Temperature Sensor........................................................................................3598 How to Install Mass Air Flow and Temperature Sensor.......................................................................................3599 Remove and Install KCCV Crankcase Pressure Sensor (Right Bank)................................................................................3600 How to Remove KCCV Crankcase Pressure Sensor (Right Bank).................................................................................3600 How to Install KCCV Crankcase Pressure Sensor (Right Bank)................................................................................3601 Remove and Install KCCV Crankcase Pressure Sensor (Left Bank).................................................................................3603 How to Remove KCCV Crankcase Pressure Sensor (Left Bank)..................................................................................3603 How to Install KCCV Crankcase Pressure Sensor (Left Bank).................................................................................3604 Remove and Install KDPF Temperature Sensor....................................................................................................3606 How to Remove KDPF Temperature Sensor.....................................................................................................3606 How to Install KDPF Temperature Sensor....................................................................................................3612 Remove and Install KDPF Differential Pressure Sensor..........................................................................................3618 How to Remove KDPF Differential Pressure Sensor...........................................................................................3618 How to Install KDPF Differential Pressure Sensor..........................................................................................3623 Remove and Install KomVision Camera...........................................................................................................3628 How to Remove KomVision Camera............................................................................................................3628 How to Install KomVision Camera...........................................................................................................3632 Remove And Install KOMTRAX Plus Controller Assembly...........................................................................................3636 How to Remove KOMTRAX Plus Controller Assembly............................................................................................3636 How to Install KOMTRAX Plus Controller Assembly...........................................................................................3637 Remove and Install Wireless LAN Unit Assembly.................................................................................................3639 How to Remove Wireless LAN Unit Assembly..................................................................................................3639 How to Install Wireless LAN Unit Assembly.................................................................................................3641 60 Maintenance Standard...............................................................................................................................3643 Table of Contents.................................................................................................................................3644 Engine and Cooling System.........................................................................................................................3645 Maintenance Standard for Engine Mount.........................................................................................................3645 Maintenance Standard for PTO..................................................................................................................3646 Maintenance Standard for Cooling Fan Pump.....................................................................................................3648 Maintenance Standard for EPC Valve of Cooling Fan Pump....................................................................................3651 Maintenance Standard for Cooling Fan Motor....................................................................................................3652 Power Train.......................................................................................................................................3655 Maintenance Standard for Swing Circle.........................................................................................................3655 Maintenance Standard for Swing Machinery......................................................................................................3656 Maintenance Standard for Final Drive..........................................................................................................3658 Maintenance Standard for Sprocket.............................................................................................................3660 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing............................................................................3661 Undercarriage and Frame...........................................................................................................................3662 Maintenance Standard for Track Frame and Idler Cushion........................................................................................3662 Maintenance Standard for Idler................................................................................................................3665 Maintenance Standard for Track Roller.........................................................................................................3667 Maintenance Standard for Carrier Roller.......................................................................................................3668 Maintenance Standard for Track Shoes..........................................................................................................3670 Maintenance Standard for Double Shoes.........................................................................................................3673 Maintenance Standard for Triple Shoes.........................................................................................................3674 Hydraulic System..................................................................................................................................3675 Maintenance Standard for Main Pump............................................................................................................3675 Maintenance Standard for Main Pump Servo Valve............................................................................................3679 Maintenance Standard for Swing Motor..........................................................................................................3681 Maintenance Standard for Travel Motor.........................................................................................................3684 Maintenance Standard for Control Valve........................................................................................................3688 Maintenance Standard for Variable Back Pressure Valve.........................................................................................3722 Maintenance Standard for PPC Cut-off Valve....................................................................................................3723 Maintenance Standard for Suction Selector Valve...............................................................................................3727 Maintenance Standard for PPC Cut-off Valve....................................................................................................3729 Maintenance Standard for Suction Selector Valve...............................................................................................3733 Maintenance Standard for Work Equipment and Swing PPC Valve...................................................................................3735 Maintenance Standard for Travel PPC Valve.....................................................................................................3738 Maintenance Standard for Center Swivel Joint..................................................................................................3741 Work Equipment....................................................................................................................................3742 Maintenance Standard for Work Equipment Linkage...............................................................................................3742 Dimensions of Arm.........................................................................................................................3746 Dimensions of Bucket......................................................................................................................3748 Maintenance Standard for Boom Cylinder........................................................................................................3751 Maintenance Standard for Arm Cylinder.........................................................................................................3752 Maintenance Standard for Bucket Cylinder......................................................................................................3753 Maintenance Standard of Work Equipment Linkage (Loading Shovel Specification..................................................................3754 Maintenance Standard of Boom Cylinder (Loading Shovel Specification)..........................................................................3757 Maintenance Standard of Arm Cylinder (Loading Shovel Specification)...........................................................................3758 Maintenance Standard of Bucket Cylinder (Loading Shovel Specification)........................................................................3759 80 Appendix...........................................................................................................................................3761 Table of Contents.................................................................................................................................3762 Precautions Before Work...........................................................................................................................3765 Air Conditioner System............................................................................................................................3766 Precautions for Refrigerant...................................................................................................................3766 Air Conditioner Component.....................................................................................................................3767 Air Conditioner Component.....................................................................................................................3769 Specifications of Air Conditioner.............................................................................................................3771 Structure and Function of Refrigeration Cycle.................................................................................................3772 Outline of Refrigeration Cycle................................................................................................................3773 Component Parts of Air Conditioner System.........................................................................................................3775 Air Conditioner Unit..........................................................................................................................3775 Configuration Diagram of Air Conditioner Unit.............................................................................................3775 Function of Air Conditioner Unit..........................................................................................................3777 Component Parts of Air Conditioner Unit.......................................................................................................3779 Function of Evaporator as Air Conditioner Unit Component..................................................................................3780 Function of Heater Core as Air Conditioner Unit Component.................................................................................3780 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component...............................................................3780 Function of Servo Motor as Air Conditioner Unit Component.................................................................................3780 Structure of Expansion Valve as Air Conditioner Unit Component............................................................................3781 Function of Expansion Valve as Air Conditioner Unit Component.............................................................................3781 Operate Expansion Valve as Air Conditioner Unit Component.................................................................................3781 Function of Dual Pressure Switch..........................................................................................................3782 Air Conditioner Controller........................................................................................................................3783 Structure of Air Conditioner Controller.......................................................................................................3783 Compressor........................................................................................................................................3784 Structure of Compressor.......................................................................................................................3784 Specifications of Compressor..................................................................................................................3785 Function of Compressor........................................................................................................................3786 Condenser.........................................................................................................................................3787 Structure of Condenser........................................................................................................................3787 Specifications of Condenser...................................................................................................................3788 Function of Condenser.........................................................................................................................3789 Receiver Drier....................................................................................................................................3790 Structure of Receiver Dryer...................................................................................................................3790 Specifications of Receiver Dryer..............................................................................................................3791 Function of Receiver Dryer....................................................................................................................3792 Air Conditioner Related Sensors...................................................................................................................3793 Function of Sunlight Sensor...................................................................................................................3793 Structure of Outside Temperature Sensor.......................................................................................................3794 Function of Outside Air Temperature Sensor....................................................................................................3795 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.......................................................................3796 Circuit Diagram and Configuration of Connector Pins of Air Conditioner............................................................................3798 System Diagram of Air Conditioner.................................................................................................................3800 Air Conditioner Control Panel.................................................................................................................3801 Structure of Air Conditioner Control Panel....................................................................................................3801 Input and Output Signals of Air Conditioner Controller........................................................................................3802 Function of Air Conditioner Controller....................................................................................................3803 Locations of Air Conditioner Parts and Layout of Connectors.......................................................................................3804 Examine Air Leakage (Duct)........................................................................................................................3808 How to Examine Air Leakage (Duct).............................................................................................................3808 Examine Air Conditioner with Self-Diagnosis Function..............................................................................................3809 Examine Vent (Mode) Changeover....................................................................................................................3811 How to Examine Vent (Mode) Changeover.........................................................................................................3811 Examine Fresh/Recirc Air Changeover...............................................................................................................3815 How to Examine Fresh/Recirc Air Changeover....................................................................................................3815 Examine Sunlight Sensor...........................................................................................................................3816 How to Examine Sunlight Sensor................................................................................................................3816 Examine Refrigerant (Dual) Pressure Switch........................................................................................................3817 How to Examine Refrigerant (Dual) Pressure Switch.............................................................................................3817 Examine Relay.....................................................................................................................................3819 How to Examine Relay..........................................................................................................................3819 Air Conditioner Troubleshooting Chart 1...........................................................................................................3820 Air Conditioner Troubleshooting Chart 2...........................................................................................................3821 KomVision System..................................................................................................................................3824 Structure and Operation of KomVision System.......................................................................................................3824 Precautions for KomVision System..............................................................................................................3824 Layout Drawing of KomVision System............................................................................................................3825 Layout Drawing of KomVision Switches and Monitors (Applicable Machine: 30001 to 30157)....................................................3826 Layout Drawing of KomVision Switches and Monitors (Applicable Machine: 30158 and up)......................................................3826 System Diagram of KomVision System........................................................................................................3827 Function of KomVision System..............................................................................................................3827 Component Parts of KomVision System...........................................................................................................3829 KomVision Controller......................................................................................................................3829 KomVision Monitor.........................................................................................................................3838 KomVision Camera..........................................................................................................................3847 Examine and Adjust KomVision System...............................................................................................................3847 Set and Operate KomVision Monitor.............................................................................................................3847 Setting Default of KomVision System.......................................................................................................3847 Touch Panel Operation (Applicable Machine: 30001 to 30157)................................................................................3848 Touch Panel Operation (Applicable Machine: 30158 and up)..................................................................................3849 Operator Mode and Maintenance Mode of KomVision Monitor...................................................................................3849 How to Operate KomVision Maintenance Mode (Applicable Machine: 30001 to 30157)............................................................3850 How to Operate KomVision Maintenance Mode (Applicable Machine: 30158 and up)..............................................................3852 How to Operate Main Settings (Applicable Machine: 30001 to 30157).........................................................................3854 How to Operate Main Settings (Applicable Machine: 30158 and up)...........................................................................3857 How to Examine System Status (Applicable Machine: 30001 to 30157).........................................................................3864 How to Examine System Status (Applicable Machine: 30158 and up)...........................................................................3865 How to Examine Error Log (Applicable Machine: 30001 to 30157).............................................................................3866 How to Examine Error Log (Applicable Machine: 30158 and up)...............................................................................3867 How to Perform Check Disk (Applicable Machine: 30001 to 30157)............................................................................3868 How to Perform Check Disk (Applicable Machine: 30158 and up)..............................................................................3868 How to Initialize KomVision Controller Setting (Applicable Machine: 30001 to 30157).......................................................3869 How to Initialize KomVision Controller Setting (Applicable Machine: 30158 and up).........................................................3870 Camera Calibration............................................................................................................................3872 7 Camera Calibration..........................................................................................................................3873 Calibration Sheet.........................................................................................................................3873 How to Operate 7 Camera Calibration.......................................................................................................3884 1 Camera Calibration..........................................................................................................................3905 How to Do 1 Camera Calibration (Applicable Machine: 30001 to 30157).......................................................................3905 How to Do 1 Camera Calibration (Applicable Machine: 30158 and up).........................................................................3909 Troubleshooting for KomVision System..............................................................................................................3914 Related Information to Troubleshooting........................................................................................................3914 Preparation for Troubleshooting of Electrical System......................................................................................3914 Procedure for Troubleshooting (Applicable Machine: 30001 to 30157)........................................................................3919 Procedure for Troubleshooting (Applicable Machine: 30158 and up)..........................................................................3922 Symptom and Troubleshooting Numbers.......................................................................................................3926 Information Shown in Troubleshooting Table................................................................................................3927 Connector List and Layout (Applicable Machine: 30001 to 30157)............................................................................3929 Connector List and Layout (Applicable Machine: 30158 and up)..............................................................................3932 Failure Code Table............................................................................................................................3935 Failure Code [DBP0KM].....................................................................................................................3937 Failure Code [DBP0KT].....................................................................................................................3938 Failure Code [DBP0MC].....................................................................................................................3939 Failure Code [DBP0NR].....................................................................................................................3940 Failure Code [DBP5KP] (Applicable Machine: 30001 to 30157)................................................................................3941 Failure Code [DBP5KP] (Applicable Machine: 30158 and up)..................................................................................3944 Failure Code [DBPLKA].....................................................................................................................3947 Failure Code [DBPLKB].....................................................................................................................3950 Failure Code [DBPRKR] (Applicable Machine: 30001 to 30157)................................................................................3952 Failure Code [DBPRKR] (Applicable Machine: 30158 and up)..................................................................................3958 Failure Code [DPQ1LD].....................................................................................................................3964 Failure Code [DPQ4KB].....................................................................................................................3965 Failure Code [DR10KA].....................................................................................................................3966 Failure Code [DR20KA].....................................................................................................................3968 Failure Code [DR30KA].....................................................................................................................3970 Failure Code [DR40KA].....................................................................................................................3972 Failure Code [DR50KA].....................................................................................................................3974 Failure Code [DR60KA].....................................................................................................................3976 Failure Code [DR90KA].....................................................................................................................3978 Troubleshooting of Electrical System (E-Mode).................................................................................................3980 E-67 KomVision Monitor Does Not Come On or Backlight Flickers (Applicable Machine: 30001 to 30157)........................................3980 E-68 KomVision Monitor Does Not Come On or Backlight Flickers (Applicable Machine: 30158 and up)..........................................3984 E-69 KomVision Monitor Images are Not Shown Clearly (Applicable Machine: 30001 to 30157)..................................................3987 E-70 KomVision Monitor Images are Not Shown Clearly (Applicable Machine: 30158 and up)....................................................3994 E-71 KomVision Monitor Cannot be Touch (Applicable Machine: 30001 to 30157)...............................................................4000 E-72 KomVision Monitor Cannot be Touch (Applicable Machine: 30158 and up).................................................................4003 E-73 Night Lighting Lamp of KomVision Monitor is Abnormal (Applicable Machine: 30001 to 30157)............................................4005 E-74 Night Lighting Lamp of KomVision Monitor is Abnormal (Applicable Machine: 30158 and up)..............................................4008 E-75 Part of Camera Image is Not Shown on the KomVision Monitor (Applicable Machine: 30001 to 30157)......................................4011 E-76 Part of Camera Image is Not Shown on the KomVision Monitor (Applicable Machine: 30158 and up)........................................4013 E-77 Image on KomVision Monitor is Not Shown Correctly After Calibration..................................................................4015 90 Circuit Diagrams...................................................................................................................................4017 Table of Contents.................................................................................................................................4018 Hydraulic Circuit Diagram.........................................................................................................................4020 Symbols Used in Hydraulic Circuit Diagram.....................................................................................................4020 Hydraulic Circuit Diagram.....................................................................................................................4025 Hydraulic Circuit Diagram(1/2) (Loading Shovel Specification).................................................................................4027 Hydraulic Circuit Diagram(2/2) (Loading Shovel Specification).................................................................................4029 Electrical Circuit Diagram........................................................................................................................4031 Symbols Used in Electric Circuit Diagram......................................................................................................4031 Electrical Circuit Diagram (1/28).............................................................................................................4035 Electrical Circuit Diagram (2/28).............................................................................................................4037 Electrical Circuit Diagram (3/28).............................................................................................................4039 Electrical Circuit Diagram (4/28).............................................................................................................4041 Electrical Circuit Diagram (5/28).............................................................................................................4043 Electrical Circuit Diagram (6/28).............................................................................................................4045 Electrical Circuit Diagram (7/28).............................................................................................................4047 Electrical Circuit Diagram (8/28).............................................................................................................4049 Electrical Circuit Diagram (9/28).............................................................................................................4051 Electrical Circuit Diagram (10/28)............................................................................................................4053 Electrical Circuit Diagram (11/28)............................................................................................................4055 Electrical Circuit Diagram (12/28)............................................................................................................4057 Electrical Circuit Diagram (13/28)............................................................................................................4059 Electrical Circuit Diagram (14/28)............................................................................................................4061 Electrical Circuit Diagram (15/28)............................................................................................................4063 Electrical Circuit Diagram (16/28)............................................................................................................4065 Electrical Circuit Diagram (17/28)............................................................................................................4067 Electrical Circuit Diagram (18/28)............................................................................................................4069 Electrical Circuit Diagram (19/28)............................................................................................................4071 Electrical Circuit Diagram (20/28)............................................................................................................4073 Electrical Circuit Diagram (21/28) (Applicable Machine: 30001 to 30157).......................................................................4075 Electrical Circuit Diagram (21/28) (Applicable Machine: 30158 and up).........................................................................4077 Electrical Circuit Diagram (22/28)............................................................................................................4079 Electrical Circuit Diagram (23/28)............................................................................................................4081 Electrical Circuit Diagram (24/28)............................................................................................................4083 Electrical Circuit Diagram (25/28)............................................................................................................4085 Electrical Circuit Diagram (26/28)............................................................................................................4087 Electrical Circuit Diagram (27/28)............................................................................................................4089 Electrical Circuit Diagram (28/28)............................................................................................................4091 Electrical Circuit Diagram (1/30) (Loading Shovel Specification)..............................................................................4093 Electrical Circuit Diagram (2/30) (Loading Shovel Specification)..............................................................................4095 Electrical Circuit Diagram (3/30) (Loading Shovel Specification)..............................................................................4097 Electrical Circuit Diagram (4/30) (Loading Shovel Specification)..............................................................................4099 Electrical Circuit Diagram (5/30) (Loading Shovel Specification)..............................................................................4101 Electrical Circuit Diagram (6/30) (Loading Shovel Specification)..............................................................................4103 Electrical Circuit Diagram (7/30) (Loading Shovel Specification)..............................................................................4105 Electrical Circuit Diagram (8/30) (Loading Shovel Specification)..............................................................................4107 Electrical Circuit Diagram (9/30) (Loading Shovel Specification)..............................................................................4109 Electrical Circuit Diagram (10/30) (Loading Shovel Specification).............................................................................4111 Electrical Circuit Diagram (11/30) (Loading Shovel Specification).............................................................................4113 Electrical Circuit Diagram (12/30) (Loading Shovel Specification).............................................................................4115 Electrical Circuit Diagram (13/30) (Loading Shovel Specification).............................................................................4117 Electrical Circuit Diagram (14/30) (Loading Shovel Specification).............................................................................4119 Electrical Circuit Diagram (15/30) (Loading Shovel Specification).............................................................................4121 Electrical Circuit Diagram (16/30) (Loading Shovel Specification).............................................................................4123 Electrical Circuit Diagram (17/30) (Loading Shovel Specification).............................................................................4125 Electrical Circuit Diagram (18/30) (Loading Shovel Specification).............................................................................4127 Electrical Circuit Diagram (19/30) (Loading Shovel Specification).............................................................................4129 Electrical Circuit Diagram (20/30) (Loading Shovel Specification).............................................................................4131 Electrical Circuit Diagram (21/30) (Loading Shovel Specification) (Applicable Machine: 30001 to 30157)........................................4133 Electrical Circuit Diagram (21/30) (Loading Shovel Specification) (Applicable Machine: 30158 and up)..........................................4135 Electrical Circuit Diagram (22/30) (Loading Shovel Specification).............................................................................4137 Electrical Circuit Diagram (23/30) (Loading Shovel Specification).............................................................................4139 Electrical Circuit Diagram (24/30) (Loading Shovel Specification).............................................................................4141 Electrical Circuit Diagram (25/30) (Loading Shovel Specification).............................................................................4143 Electrical Circuit Diagram (26/30) (Loading Shovel Specification).............................................................................4145 Electrical Circuit Diagram (27/30) (Loading Shovel Specification).............................................................................4147 Electrical Circuit Diagram (28/30) (Loading Shovel Specification).............................................................................4149 Electrical Circuit Diagram (29/30) (Loading Shovel Specification).............................................................................4151 Electrical Circuit Diagram (30/30) (Loading Shovel Specification).............................................................................4153 Index..................................................................................................................................................4155
DESCRIPTION:
KOMATSU PC2000-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06651-14 – 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 Specification
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 Others
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 30/12/24
