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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C8 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C8 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C8 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C8 – PDF DOWNLOAD
Language : English
Pages : 2538
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C8 – PDF DOWNLOAD
00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 17 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 22 HOW TO READ THE SHOP MANUAL..................................................................................................... 22 SAFETY NOTICE FOR OPERATION..................................................................................................... 24 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 32 ACTIONS IF FIRE OCCURS.......................................................................................................... 33 PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS................................................................................. 34 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 35 PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS............................................................................. 38 PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT................................................................................ 45 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 47 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 48 PRACTICAL USE OF KOMTRAX........................................................................................................ 49 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 50 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 50 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 51 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 52 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 54 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 59 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 61 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 62 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 64 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 65 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 69 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 72 CONVERSION TABLE................................................................................................................ 79 01 SPECIFICATION........................................................................................................................ 85 CONTENTS............................................................................................................................ 86 ABBREVIATION LIST................................................................................................................... 87 SPECIFICATIONS...................................................................................................................... 92 SPECIFICATION DRAWING........................................................................................................... 92 SPECIFICATION DRAWING: PC210-10M0........................................................................................... 92 SPECIFICATION DRAWING: PC210LC-10M0......................................................................................... 93 WORKING RANGE DRAWINGS.......................................................................................................... 95 WORKING RANGE DRAWINGS: PC210-10M0.......................................................................................... 95 WORKING RANGE DRAWINGS: PC210LC-10M0........................................................................................ 96 SPECIFICATIONS.................................................................................................................. 98 SPECIFICATION: PC210-10M0................................................................................................... 98 SPECIFICATIONS: PC210LC-10M0................................................................................................ 100 WEIGHT TABLE.................................................................................................................... 104 WEIGHT TABLE: PC210-10M0.................................................................................................... 104 WEIGHT TABLE: PC210LC-10M0.................................................................................................. 105 FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE......................................................................... 107 10 STRUCTURE AND FUNCTION............................................................................................................... 109 CONTENTS............................................................................................................................ 110 ABBREVIATION LIST................................................................................................................... 113 BOOT-UP SYSTEM...................................................................................................................... 118 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 118 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 119 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 119 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 119 OPERATION OF SYSTEM OPERATING LAMP.......................................................................................... 119 BATTERY DISCONNECT SWITCH....................................................................................................... 120 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 120 OPERATION OF BATTERY DISCONNECT SWITCH...................................................................................... 120 ENGINE SYSTEM....................................................................................................................... 121 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 121 ENGINE CONTROL SYSTEM........................................................................................................... 122 ENGINE CONTROL SYSTEM DRAWING............................................................................................... 122 OPERATION OF ENGINE CONTROL SYSTEM.......................................................................................... 122 AUTO-DECELERATION SYSTEM........................................................................................................ 124 AUTO-DECELERATION SYSTEM DRAWING............................................................................................ 124 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 124 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 125 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 126 ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING..................................................................................... 126 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 127 OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................ 127 OVERHEAT PREVENTION SYSTEM...................................................................................................... 128 OVERHEAT PREVENTION SYSTEM DRAWING.......................................................................................... 128 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 129 OPERATION OF OVERHEAT PREVENTION SYSTEM..................................................................................... 129 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 131 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 131 COOLING SYSTEM...................................................................................................................... 132 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 132 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 133 CONTROL SYSTEM...................................................................................................................... 134 LAYOUT DRAWING OF CONTROL SYSTEM PARTS.......................................................................................... 134 MACHINE MONITOR SYSTEM.......................................................................................................... 136 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 136 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 136 KOMTRAX SYSTEM.................................................................................................................. 138 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 138 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 138 CONTROL SYSTEM.................................................................................................................. 139 MACHINE MONITOR............................................................................................................. 139 KOMTRAX TERMINAL............................................................................................................ 150 PUMP CONTROLLER............................................................................................................. 153 RESISTOR FOR PC-EPC VALVE................................................................................................... 157 CAN TERMINATING RESISTOR.................................................................................................... 157 ENGINE CONTROLLER........................................................................................................... 158 FUEL CONTROL DIAL........................................................................................................... 162 HYDRAULIC SYSTEM.................................................................................................................... 163 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 163 CLSS............................................................................................................................ 166 CLSS SYSTEM DIAGRAM......................................................................................................... 166 FUNCTION OF CLSS............................................................................................................ 167 PRESSURE COMPENSATION CONTROL............................................................................................... 184 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 185 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 185 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 186 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 190 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 190 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 191 HYDRAULIC SYSTEM................................................................................................................ 193 HYDRAULIC TANK.............................................................................................................. 193 MAIN PUMP................................................................................................................... 195 CONTROL VALVE............................................................................................................... 215 WORK EQUIPMENT SYSTEM............................................................................................................... 261 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 261 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 265 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 265 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 266 PPC LOCK SYSTEM................................................................................................................. 267 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 267 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 268 ATTACHMENT OIL FLOW ADJUSTER SYSTEM............................................................................................. 269 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................. 269 FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM............................................................................. 270 WORK EQUIPMENT SYSTEM........................................................................................................... 271 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 271 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 275 2ND-LINE ATTACHMENT PPC VALVE............................................................................................... 279 SOLENOID VALVE.............................................................................................................. 283 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)....................................................................... 285 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)........................................................................ 287 PILOT CIRCUIT ACCUMULATOR................................................................................................... 290 ATTACHMENT CIRCUIT ACCUMULATOR.............................................................................................. 290 SWING SYSTEM........................................................................................................................ 293 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 293 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 295 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 295 SWING SYSTEM.................................................................................................................... 299 SWING MOTOR................................................................................................................. 299 SWING MACHINERY............................................................................................................. 307 SWING CIRCLE................................................................................................................ 310 TRAVEL SYSTEM....................................................................................................................... 311 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 311 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 313 FUNCTION OF TRAVEL CONTROL SYSTEM............................................................................................... 314 TRAVEL SYSTEM................................................................................................................... 315 TRAVEL MOTOR................................................................................................................ 315 FINAL DRIVE................................................................................................................. 326 TRAVEL PPC VALVE............................................................................................................ 327 CENTER SWIVEL JOINT......................................................................................................... 332 FUNCTION OF SWING CIRCLE............................................................................................................ 334 UNDERCARRIAGE AND FRAME............................................................................................................. 335 LAYOUT DRAWING OF UNDERCARRIAG.................................................................................................. 335 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 335 WORK EQUIPMENT...................................................................................................................... 337 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 337 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 338 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 338 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 339 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 339 CAB RELATED PARTS................................................................................................................... 340 ROPS CAB........................................................................................................................ 340 STRUCTURE OF ROPS CAB....................................................................................................... 340 FUNCTION OF ROPS CAB........................................................................................................ 340 CAB MOUNT....................................................................................................................... 341 STRUCTURE OF CAB MOUNT...................................................................................................... 341 FUNCTION OF CAB MOUNT....................................................................................................... 342 CAB TIPPING STOPPER............................................................................................................. 343 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 343 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 343 20 STANDARD VALUE TABLE................................................................................................................. 345 CONTENTS............................................................................................................................ 346 ABBREVIATION LIST................................................................................................................... 347 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 352 STANDARD VALUE TABLE FOR ENGINE: PC210-10M0..................................................................................... 352 STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0................................................................................... 356 STANDARD VALUE TABLE FOR MACHINE: PC210-10M0.................................................................................... 360 STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0.................................................................................. 374 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE........................................................................... 388 30 TESTING AND ADJUSTING................................................................................................................ 391 CONTENTS............................................................................................................................ 392 ABBREVIATION LIST................................................................................................................... 395 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 400 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 400 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 405 ENGINE AND COOLING SYSTEM........................................................................................................... 407 TEST ENGINE SPEED............................................................................................................... 407 TEST ENGINE HIGH IDLE SPEED................................................................................................. 407 Test engine low idle speed.................................................................................................. 407 TEST ENGINE SPEED AT 2 PUMPS RELIEF......................................................................................... 407 Test engine speed at 2 pumps relief and one-touch power maximizing.......................................................... 408 TEST ENGINE SPEED WITH AUTO-DECELERATION.................................................................................... 408 Test boost pressure............................................................................................................. 410 TEST BOOST PRESSURE ON MACHINE MONITOR...................................................................................... 410 TEST BOOST PRESSURE BY TESTING TOOL......................................................................................... 411 TEST EXHAUST GAS COLOR.......................................................................................................... 413 Test exhaust gas color by handy smoke checker............................................................................... 413 TEST EXHAUST GAS COLOR BY SMOKE METER....................................................................................... 414 TEST MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................................... 416 TEST MASS AIR FLOW AND TEMPERATURE SENSOR................................................................................... 416 Test and adjust valve clearance................................................................................................. 418 TEST VALVE CLEARANCE........................................................................................................ 418 Adjust valve clearance...................................................................................................... 419 TEST COMPRESSION PRESSURE....................................................................................................... 421 TEST COMPRESSION PRESSURE................................................................................................... 421 TEST BLOWBY PRESSURE............................................................................................................ 424 TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT))......................................... 424 Test blowby pressure (machine without blowby pressure sensor)............................................................... 425 TEST ENGINE OIL PRESSURE........................................................................................................ 427 TEST ENGINE OIL PRESSURE.................................................................................................... 427 Test fuel pressure.............................................................................................................. 429 TEST FUEL PRESSURE.......................................................................................................... 430 Test fuel discharged volume, return rate, and leakage........................................................................... 436 TEST FUEL DISCHARGE, RETURN AND LEAKAGE..................................................................................... 437 BLEED AIR FROM FUEL SYSTEM...................................................................................................... 442 Bleed air from fuel system.................................................................................................. 442 Test fuel system for leakage.................................................................................................... 444 Test fuel circuit for leakage............................................................................................... 444 CYLINDER CUT-OUT MODE OPERATION................................................................................................. 446 NO-INJECTION CRANKING OPERATION................................................................................................. 447 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 448 CHECK AIR CONDITIONER COMPRESSOR BELT....................................................................................... 448 ADJUST AIR CONDITIONER COMPRESSOR BELT...................................................................................... 448 POWER TRAIN......................................................................................................................... 450 Test swing circle bearing clearance............................................................................................. 450 Test swing circle bearing clearance......................................................................................... 450 UNDERCARRIAGE AND FRAME............................................................................................................. 451 Test and adjust track shoe tension.............................................................................................. 451 Test track shoe tension..................................................................................................... 451 Adjust track shoe tension................................................................................................... 451 HYDRAULIC SYSTEM.................................................................................................................... 453 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 453 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.............................................................................. 453 Release remaining pressure in hydraulic cylinder circuit.................................................................... 453 Release remaining pressure for machines without anti-drop valve............................................................. 453 Release remaining pressure for machines with boom anti-drop valve........................................................... 453 Release remaining pressure from swing motor circuit......................................................................... 455 RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT........................................................................ 455 Test and adjust oil pressure in work equipment, swing, and travel circuits...................................................... 456 Test oil pressure in work equipment, swing, and travel circuits............................................................. 456 Adjust oil pressure in work equipment, swing, and travel circuits........................................................... 463 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 466 Test oil pressure of control circuit........................................................................................ 466 Test and adjust oil pressure in pump PC control circuit......................................................................... 468 Test PC valve outlet pressure (servo piston inlet pressure)................................................................. 468 TEST PC-EPC VALVE OUTLET PRESSURE........................................................................................... 469 Adjust oil pressure in pump PC control circuit.............................................................................. 471 Test and adjust oil pressure in pump LS control circuit......................................................................... 472 Test LS differential pressure with machine monitor.......................................................................... 472 Test LS differential pressure by testing tool............................................................................... 474 Test LS valve outlet pressure (servo piston inlet pressure)................................................................. 476 Test LS-EPC valve outlet pressure........................................................................................... 477 Adjust LS valve............................................................................................................. 478 Test outlet pressure of solenoid valve.......................................................................................... 480 Test outlet pressure of solenoid valve...................................................................................... 480 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 482 Test PPC valve outlet pressure.................................................................................................. 484 Test outlet pressure of PPC valve with machine monitor...................................................................... 484 TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL........................................................................... 485 Adjust play of work equipment and swing PPC valve............................................................................... 487 Adjust play of work equipment and swing PPC valve........................................................................... 487 TesTest pump swash plate sensor................................................................................................. 488 Test pump swash plate sensor................................................................................................ 488 Test parts causing hydraulic drift in work equipment............................................................................ 489 Test parts causing hydraulic drift of boom cylinder and bucket cylinder..................................................... 489 Test parts causing hydraulic drift of arm cylinder.......................................................................... 489 Test parts causing hydraulic drift of boom hydraulic drift prevention valve................................................. 490 Test parts causing hydraulic drift of PPC valve............................................................................. 490 Test oil leakage................................................................................................................ 491 TEST OIL LEAKAGE FROM BOOM CYLINDER......................................................................................... 491 TEST OIL LEAKAGE FROM ARM CYLINDER.......................................................................................... 492 TEST OIL LEAKAGE FROM BUCKET CYLINDER....................................................................................... 493 Test oil leakage from swing motor........................................................................................... 493 Test oil leakage from travel motor.......................................................................................... 494 Bleed air from hydraulic system................................................................................................. 496 Bleed air from main pump.................................................................................................... 497 BLEED AIR FROM CYLINDER..................................................................................................... 498 BLEED AIR FROM SWING MOTOR.................................................................................................. 499 BLEED AIR FROM TRAVEL MOTOR................................................................................................. 499 CAB RELATED PARTS................................................................................................................... 501 Test cab tipping stopper........................................................................................................ 501 Test cab tipping stopper.................................................................................................... 501 ADJUST MIRRORS.................................................................................................................. 502 ADJUST MACHINE LEFT FRONT MIRROR (A)........................................................................................ 502 Adjust regular position of machine left front mirror (A).................................................................... 503 ADJUST MACHINE RIGHT FRONT MIRROR (B)....................................................................................... 504 ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)................................................................... 504 ADJUST MACHINE RIGHT SIDE MIRROR (C)........................................................................................ 505 ELECTRICAL SYSTEM................................................................................................................... 507 SETTING AND OPERATION OF MACHINE MONITOR........................................................................................ 507 OPERATOR MODE............................................................................................................... 511 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 511 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 511 CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY).............................................................................. 512 CHECK FUNCTION OF SERVICE METER............................................................................................. 512 SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD........................................................................ 512 SERVICE MODE................................................................................................................ 515 Operation of service mode................................................................................................... 515 Check pre-defined monitoring information.................................................................................... 516 CHECK MONITORING INFORMATION................................................................................................ 520 ABNORMALITY RECORD MENU..................................................................................................... 528 CHECK MAINTENANCE RECORD.................................................................................................... 531 MAINTENANCE MODE SETTING.................................................................................................... 533 Phone number entry setting.................................................................................................. 537 DEFAULT SETTING MENU........................................................................................................ 538 TESTING MENU................................................................................................................ 546 ADJUSTMENT MENU............................................................................................................. 548 NO-INJECTION CRANKING OPERATION............................................................................................. 565 KOMTRAX SETTINGS MENU....................................................................................................... 568 Display service message..................................................................................................... 570 START UP KOMTRAX TERMINAL....................................................................................................... 571 Adjust rearview camera angle.................................................................................................... 575 ADJUST REARVIEW CAMERA ANGLE................................................................................................ 575 ENGINE CONTROLLER VOLTAGE CIRCUIT............................................................................................... 577 TEST DIODES..................................................................................................................... 578 TEST DIODES BY DIGITAL TESTER............................................................................................... 578 TEST DIODES BY ANALOG TESTER................................................................................................ 578 Pm-CLINIC........................................................................................................................... 579 PM CLINIC SERVICE............................................................................................................... 579 PM CLINIC CHECK SHEET: PC210-10M0........................................................................................... 582 PM CLINIC CHECK SHEET: PC210LC-10M0......................................................................................... 590 40 TROUBLESHOOTING...................................................................................................................... 599 ABBREVIATION LIST................................................................................................................... 600 CONTENTS............................................................................................................................ 605 RELATED INFORMATION FOR TROUBLESHOOTING............................................................................................. 611 PRECAUTIONS FOR TROUBLESHOOTING................................................................................................. 611 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 612 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 614 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 616 WALK-AROUND CHECK........................................................................................................... 616 TEST ENGINE RELATED PARTS................................................................................................... 617 TEST WORK EQUIPMENT AND UNDERCARRIAGE....................................................................................... 619 CHECK ELECTRIC EQUIPMENT.................................................................................................... 620 CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER...................................................................................... 625 CONNECT ADAPTER TO TROUBLESHOOT MONITOR..................................................................................... 625 CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER............................................................................. 627 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL............................................................................ 631 CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER........................................................................... 633 CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR............................................................... 634 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH.............................................................................. 636 DISCONNECT AND CONNECT DEUTSCH CONNECTOR.................................................................................... 636 DISCONNECT AND CONNECT BOSCH CONNECTOR...................................................................................... 636 DISCONNECT AND CONNECT AMP CONNECTOR........................................................................................ 637 DISCONNECT AND CONNECT SUMITOMO CONNECTOR................................................................................... 638 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL.............................................................................. 639 DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR............................................................... 639 DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR..................................................................................... 640 DISCONNECT AND CONNECT FRAMATOME CONNECTOR.................................................................................. 640 DISCONNECT AND CONNECT TYCO CONNECTOR....................................................................................... 641 DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE......................................................................... 642 PROCEDURE FOR TROUBLESHOOTING................................................................................................... 643 INFORMATION DESCRIBED IN TROUBLESHOOTING........................................................................................ 644 DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS........................................................ 647 CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE............................................................................... 650 CONNECTOR LAYOUT................................................................................................................ 724 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 730 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 772 FUSE LOCATION AND CONNECTION TABLE.............................................................................................. 778 DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING............................................................... 781 FAILURE CODES TABLE............................................................................................................. 783 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................... 791 FAILURE CODE [602KNX]........................................................................................................... 791 FAILURE CODE [6AZ0ZG]........................................................................................................... 794 FAILURE CODE [879AKA]........................................................................................................... 798 FAILURE CODE [879AKB]........................................................................................................... 800 FAILURE CODE [879BKA]........................................................................................................... 802 FAILURE CODE [879BKB]........................................................................................................... 805 FAILURE CODE [879CKA]........................................................................................................... 808 FAILURE CODE [879CKB]........................................................................................................... 810 FAILURE CODE [879DKZ]........................................................................................................... 812 FAILURE CODE [879EMC]........................................................................................................... 816 FAILURE CODE [879FMC]........................................................................................................... 818 FAILURE CODE [879GKX]........................................................................................................... 820 FAILURE CODE [989L00]........................................................................................................... 823 FAILURE CODE [989M00]........................................................................................................... 825 FAILURE CODE [989N00]........................................................................................................... 827 FAILURE CODE [AA10NX]........................................................................................................... 828 FAILURE CODE [AB00KE]........................................................................................................... 831 FAILURE CODE [B@BAZG]........................................................................................................... 835 FAILURE CODE [B@BAZK]........................................................................................................... 839 FAILURE CODE [B@BCZK]........................................................................................................... 842 FAILURE CODE [B@BCNS]........................................................................................................... 844 FAILURE CODE [B@BCQA]........................................................................................................... 848 FAILURE CODE [B@HANS]........................................................................................................... 850 FAILURE CODE [CA111]............................................................................................................ 853 FAILURE CODE [CA115]............................................................................................................ 858 ENGINE Ne (CRANKSHAFT) SPEED SENSOR......................................................................................... 864 FAILURE CODE [CA122]............................................................................................................ 866 FAILURE CODE [CA123]............................................................................................................ 869 FAILURE CODE [CA131]............................................................................................................ 873 FAILURE CODE [CA132]............................................................................................................ 876 FAILURE CODE [CA144]............................................................................................................ 880 FAILURE CODE [CA145]............................................................................................................ 884 FAILURE CODE [CA153]............................................................................................................ 888 FAILURE CODE [CA154]............................................................................................................ 892 FAILURE CODE [CA155]............................................................................................................ 896 FAILURE CODE [CA187]............................................................................................................ 898 FAILURE CODE [CA221]............................................................................................................ 901 FAILURE CODE [CA222]............................................................................................................ 904 FAILURE CODE [CA227]............................................................................................................ 907 FAILURE CODE [CA234]............................................................................................................ 910 FAILURE CODE [CA238]............................................................................................................ 912 FAILURE CODE [CA271]............................................................................................................ 915 FAILURE CODE [CA272]............................................................................................................ 918 FAILURE CODE [CA322]............................................................................................................ 920 FAILURE CODE [CA323]............................................................................................................ 924 FAILURE CODE [CA324]............................................................................................................ 928 FAILURE CODE [CA325]............................................................................................................ 932 FAILURE CODE [CA331]............................................................................................................ 936 FAILURE CODE [CA332]............................................................................................................ 940 FAILURE CODE [CA342]............................................................................................................ 944 FAILURE CODE [CA351]............................................................................................................ 949 FAILURE CODE [CA352]............................................................................................................ 954 FAILURE CODE [CA386]............................................................................................................ 957 FAILURE CODE [CA435]............................................................................................................ 959 FAILURE CODE [CA441]............................................................................................................ 962 FAILURE CODE [CA442]............................................................................................................ 967 FAILURE CODE [CA449]............................................................................................................ 971 FAILURE CODE [CA451]............................................................................................................ 977 FAILURE CODE [CA452]............................................................................................................ 980 FAILURE CODE [CA488]............................................................................................................ 983 FAILURE CODE [CA553]............................................................................................................ 986 FAILURE CODE [CA559]............................................................................................................ 991 TEST LOW PRESSURE FUEL CIRCUIT DEVICES...................................................................................... 997 FAILURE CODE [CA689]............................................................................................................ 999 FAILURE CODE [CA731]............................................................................................................1004 INSTALLATION POINTS OF CRANKSHAFT AND CAMSHAFT SPEED SENSORS................................................................1007 FAILURE CODE [CA757]............................................................................................................1009 FAILURE CODE [CA778]............................................................................................................1014 ENGINE Ne (CRANKSHAFT) SPEED SENSOR.........................................................................................1019 FAILURE CODE [CA2185]...........................................................................................................1021 FAILURE CODE [CA2186]...........................................................................................................1023 FAILURE CODE [CA2249]...........................................................................................................1026 TEST LOW PRESSURE FUEL CIRCUIT DEVICES......................................................................................1032 FAILURE CODE [CA2311]...........................................................................................................1034 FAILURE CODE [CA2555]...........................................................................................................1041 FAILURE CODE [CA2556]...........................................................................................................1045 FAILURE CODE [D110KB]...........................................................................................................1049 FAILURE CODE [D19JKZ]...........................................................................................................1052 FAILURE CODE [D1N0KA]...........................................................................................................1057 FAILURE CODE [D1N0KB]...........................................................................................................1060 FAILURE CODE [D1N0KY]...........................................................................................................1063 FAILURE CODE [D811MC]...........................................................................................................1065 FAILURE CODE [D862KA]...........................................................................................................1066 FAILURE CODE [D8AQKR]...........................................................................................................1068 FAILURE CODE [D8ALKA]...........................................................................................................1076 FAILURE CODE [D8ALKB]...........................................................................................................1080 FAILURE CODE [DA20MC]...........................................................................................................1083 FAILURE CODE [DA22KK]...........................................................................................................1084 FAILURE CODE [DA25KP]...........................................................................................................1089 FAILURE CODE [DA26KP]...........................................................................................................1093 FAILURE CODE [DA29KQ]...........................................................................................................1099 FAILURE CODE [DA2LKA]...........................................................................................................1104 FAILURE CODE [DA2LKB]...........................................................................................................1108 FAILURE CODE [DA2QKR]...........................................................................................................1111 FAILURE CODE [DA2RKR]...........................................................................................................1120 FAILURE CODE [DAF0MB]...........................................................................................................1128 FAILURE CODE [DAF0MC]...........................................................................................................1129 FAILURE CODE [DAF9KQ]...........................................................................................................1130 FAILURE CODE [DAFGMC]...........................................................................................................1132 FAILURE CODE [DAFLKA]...........................................................................................................1133 FAILURE CODE [DAFLKB]...........................................................................................................1137 FAILURE CODE [DAFQKR]...........................................................................................................1140 FAILURE CODE [DAZ9KQ]...........................................................................................................1149 FAILURE CODE [DAZQKR]...........................................................................................................1151 FAILURE CODE [DB2QKR]...........................................................................................................1159 FAILURE CODE [DDPAKA]...........................................................................................................1168 FAILURE CODE [DGH2KA]...........................................................................................................1171 FAILURE CODE [DGH2KB]...........................................................................................................1174 FAILURE CODE [DHA4KA]...........................................................................................................1177 FAILURE CODE [DHE5MA]...........................................................................................................1180 FAILURE CODE [DHPAMA]...........................................................................................................1184 FAILURE CODE [DHPBMA]...........................................................................................................1188 FAILURE CODE [DHS3MA]...........................................................................................................1192 FAILURE CODE [DHS4MA]...........................................................................................................1196 FAILURE CODE [DHS8MA]...........................................................................................................1200 FAILURE CODE [DHS9MA]...........................................................................................................1204 FAILURE CODE [DHSAMA]...........................................................................................................1208 FAILURE CODE [DHSBMA]...........................................................................................................1212 FAILURE CODE [DHSCMA]...........................................................................................................1216 FAILURE CODE [DHSDMA]...........................................................................................................1220 FAILURE CODE [DHSFMA]...........................................................................................................1224 FAILURE CODE [DHSGMA]...........................................................................................................1228 FAILURE CODE [DHSHMA]...........................................................................................................1232 FAILURE CODE [DHSJMA]...........................................................................................................1236 FAILURE CODE [DJG1KX]...........................................................................................................1240 FAILURE CODE [DKR0MA]...........................................................................................................1244 FAILURE CODE [DKR1MA]...........................................................................................................1248 FAILURE CODE [DKR2MA]...........................................................................................................1252 FAILURE CODE [DKR2NX]...........................................................................................................1256 FAILURE CODE [DLM5KA]...........................................................................................................1258 FAILURE CODE [DLM5MB]...........................................................................................................1262 FAILURE CODE [DR21KX]...........................................................................................................1266 FAILURE CODE [DR31KX]...........................................................................................................1269 FAILURE CODE [DV20KB]...........................................................................................................1270 FAILURE CODE [DW43KA]...........................................................................................................1273 FAILURE CODE [DW43KB]...........................................................................................................1276 FAILURE CODE [DW43KY]...........................................................................................................1279 FAILURE CODE [DW45KA]...........................................................................................................1281 FAILURE CODE [DW45KB]...........................................................................................................1285 FAILURE CODE [DW45KY]...........................................................................................................1289 FAILURE CODE [DW91KA]...........................................................................................................1292 FAILURE CODE [DW91KB]...........................................................................................................1294 FAILURE CODE [DW91KY]...........................................................................................................1297 FAILURE CODE [DW97KA]...........................................................................................................1299 FAILURE CODE [DW97KB]...........................................................................................................1301 FAILURE CODE [DW97KY]...........................................................................................................1304 FAILURE CODE [DWA2KA]...........................................................................................................1306 FAILURE CODE [DWA2KB]...........................................................................................................1308 FAILURE CODE [DWA2KY]...........................................................................................................1311 FAILURE CODE [DWK0KA]...........................................................................................................1313 FAILURE CODE [DWK0KB]...........................................................................................................1315 FAILURE CODE [DWK0KY]...........................................................................................................1318 FAILURE CODE [DWK2KA]...........................................................................................................1320 FAILURE CODE [DWK2KB]...........................................................................................................1322 FAILURE CODE [DWK2KY]...........................................................................................................1325 FAILURE CODE [DWK8KA]...........................................................................................................1327 FAILURE CODE [DWK8KB]...........................................................................................................1329 FAILURE CODE [DWK8KY]...........................................................................................................1332 FAILURE CODE [DWN5KA]...........................................................................................................1334 FAILURE CODE [DWN5KB]...........................................................................................................1337 FAILURE CODE [DWN5KY]...........................................................................................................1341 FAILURE CODE [DXA8KA]...........................................................................................................1343 FAILURE CODE [DXA8KB]...........................................................................................................1346 FAILURE CODE [DXA9KA]...........................................................................................................1350 FAILURE CODE [DXA9KB]...........................................................................................................1353 FAILURE CODE [DXE0KA]...........................................................................................................1357 FAILURE CODE [DXE0KB]...........................................................................................................1359 FAILURE CODE [DXE4KA]...........................................................................................................1362 FAILURE CODE [DXE4KB]...........................................................................................................1364 FAILURE CODE [DXE4KY]...........................................................................................................1367 FAILURE CODE [DXE5KA]...........................................................................................................1369 FAILURE CODE [DXE5KB]...........................................................................................................1371 FAILURE CODE [DXE6KA]...........................................................................................................1374 FAILURE CODE [DXE6KB]...........................................................................................................1376 FAILURE CODE [DY20KA]...........................................................................................................1379 FAILURE CODE [DY20MA]...........................................................................................................1383 FAILURE CODE [DY2CKB]...........................................................................................................1387 FAILURE CODE [DY2DKB]...........................................................................................................1392 FAILURE CODE [DY2EKB]...........................................................................................................1395 FAILURE CODE [F@BBZL]...........................................................................................................1398 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1401 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...................................................................................1401 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................................................1411 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK.......................................................................................1415 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP..........................................................1419 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.................................................1424 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW..........1429 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW....1431 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION.......................................................1433 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION........................................................1435 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION....................................................1437 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION..............................................................1439 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION................................................................1443 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...........................................................1444 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION................................................1445 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.......................................................1447 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.................................................1448 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM................................................................................1450 FUEL GAUGE INDICATES INCORRECT LEVEL............................................................................................1453 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM.................................................................1455 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE.......................................................................1456 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM...........................................................1458 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE.................................................................1461 MACHINE MONITOR SHOWS INCORRECT MODEL...........................................................................................1463 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED..........................................................................1464 FUNCTION SWITCH DOES NOT OPERATE................................................................................................1465 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER).....................................................................1466 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED................................1468 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION..................................................1469 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED....................................................1472 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED.....................................................1473 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED......................................................1474 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED......................................................................1475 ALARM BUZZER DOES NOT STOP......................................................................................................1477 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION.........................................................1478 MACHINE DOES NOT CHANGE TO SERVICE MODE.........................................................................................1479 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE............................................................................1480 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK...............................................................................1484 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED.....................................................1486 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON...................................................................1490 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY.......................................1493 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED.............................................................................1497 TRAVEL ALARM DOES NOT SOUND.....................................................................................................1499 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS...................................................................................1502 HORN DOES NOT SOUND.............................................................................................................1504 HORN DOES NOT STOP..............................................................................................................1508 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED........................................................1510 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED............................................................................1511 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED............................................................1514 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.......................................................................1517 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.......................................................................1518 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.....................................................................1519 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION...........................................................................1520 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.................................................................1521 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.................................................................1522 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION............................................................................1523 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION...........................................................................1524 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION..................................................................1525 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................1528 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY........................................................................................1530 QUICK COUPLER DOES NOT WORK.....................................................................................................1532 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1537 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE).........................................................................1537 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK...............................................................................1538 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER......................................................................1540 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR....................................................................................1553 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...............................................................................1558 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS......................................................................................1560 BOOM SPEED OR POWER IS LOW......................................................................................................1569 Arm speed or power is low.......................................................................................................1581 BUCKET SPEED OR POWER IS LOW....................................................................................................1592 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION................................................................................1602 HYDRAULIC DRIFT OF BOOM IS LARGE................................................................................................1606 HYDRAULIC DRIFT OF ARM IS LARGE.................................................................................................1608 HYDRAULIC DRIFT OF BUCKET IS LARGE..............................................................................................1612 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES................................................1615 TIME LAG OF WORK EQUIPMENT IS LARGE.............................................................................................1617 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE............................................................................1624 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................1627 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED................................................................................1629 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER...............................................1631 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY...........................................................1633 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW...........................................................1634 MACHINE DOES NOT TRAVEL STRAIGHT................................................................................................1635 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW............................................................................1646 TRAVEL SPEED IS SLOW............................................................................................................1661 ONE OF TRACKS DOES NOT RUN......................................................................................................1672 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST...............................................................1681 MACHINE DOES NOT SWING TO RIGHT OR LEFT.........................................................................................1684 SWINGS ONLY IN ONE DIRECTION....................................................................................................1689 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)....................................................1692 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION..................................................................1699 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...............................................1703 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)...........................1705 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS.......................................................................................1709 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS.........................................................................1711 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)..........................................................1714 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED).........................................................1716 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE).......................................................................1720 UNUSUAL NOISE IS HEARD FROM AROUND FAN..........................................................................................1722 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1723 CONTENTS............................................................................................................................1724 ABBREVIATION LIST...................................................................................................................1728 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................1733 HOW TO READ THIS MANUAL.........................................................................................................1733 COATING MATERIALS LIST..........................................................................................................1735 SPECIAL TOOLS LIST..............................................................................................................1740 SKETCHES OF SPECIAL TOOLS.......................................................................................................1749 PREPARATION.........................................................................................................................1755 DRAIN AND ADD COOLANT...........................................................................................................1755 DRAIN COOLANT...............................................................................................................1755 ADD COOLANT.................................................................................................................1756 DRAIN AND AD HYDRAULIC OIL......................................................................................................1758 DRAIN HYDRAULIC OIL.........................................................................................................1758 ADD HYDRAULIC OIL...........................................................................................................1760 DRAIN AND ADD FUEL..............................................................................................................1762 DRAIN FUEL..................................................................................................................1762 ADD FUEL....................................................................................................................1763 COLLECT AND REFILL REFRIGERANT..................................................................................................1766 COLLECT REFRIGERANT.........................................................................................................1766 REFILL REFRIGERANT..........................................................................................................1766 ENGINE AND COOLING SYSTEM...........................................................................................................1767 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................1767 REMOVE SUPPLY PUMP ASSEMBLY.................................................................................................1768 INSTALL SUPPLY PUMP ASSEMBLY................................................................................................1772 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................1776 REMOVE INJECTOR ASSEMBLY....................................................................................................1777 INSTALL INJECTOR ASSEMBLY...................................................................................................1780 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................1787 REMOVE CYLINDER HEAD ASSEMBLY...............................................................................................1788 INSTALL CYLINDER HEAD ASSEMBLY..............................................................................................1799 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY......................................................................................1814 REMOVE STARTING MOTOR ASSEMBLY..............................................................................................1814 INSTALL STARTING MOTOR ASSEMBLY.............................................................................................1816 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................1819 REMOVE ALTERNATOR BELT......................................................................................................1819 INSTALL ALTERNATOR BELT.....................................................................................................1823 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................1826 REMOVE RADIATOR ASSEMBLY....................................................................................................1826 INSTALL RADIATOR ASSEMBLY...................................................................................................1829 REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY....................................................................................1832 REMOVE HYDRAULIC COOLER ASSEMBLY............................................................................................1833 INSTALL HYDRAULIC COOLER ASSEMBLY...........................................................................................1836 REMOVE AND INSTALL AFTER COOLER ASSEMBLY........................................................................................1839 REMOVE AFTER COOLER ASSEMBLY................................................................................................1839 INSTALL AFTER COOLER ASSEMBLY...............................................................................................1841 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY..........................................................................................1845 REMOVE FAN CLUTCH ASSEMBLY..................................................................................................1846 INSTALL FAN CLUTCH ASSEMBLY.................................................................................................1850 REMOVE AND INSTALL FAN..........................................................................................................1856 REMOVE FAN..................................................................................................................1856 INSTALL FAN.................................................................................................................1856 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................1857 REMOVE ENGINE AND MAIN PUMP ASSEMBLY........................................................................................1858 INSTALL ENGINE AND MAIN PUMP ASSEMBLY.......................................................................................1874 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................1891 REMOVE ENGINE FRONT OIL SEAL................................................................................................1891 INSTALL ENGINE FRONT OIL SEAL...............................................................................................1894 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................1897 REMOVE ENGINE REAR OIL SEAL.................................................................................................1897 INSTALL ENGINE REAR OIL SEAL................................................................................................1899 REMOVE AND INSTALL FUEL COOLER ASSEMBLY.........................................................................................1903 REMOVE FUEL COOLER ASSEMBLY.................................................................................................1903 INSTALL FUEL COOLER ASSEMBLY................................................................................................1904 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................1906 REMOVE ENGINE HOOD ASSEMBLY.................................................................................................1906 INSTALL ENGINE HOOD ASSEMBLY................................................................................................1908 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................1910 REMOVE FUEL TANK ASSEMBLY...................................................................................................1911 INSTALL FUEL TANK ASSEMBLY..................................................................................................1915 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................1921 REMOVE AIR CLEANER ASSEMBLY.................................................................................................1921 INSTALL AIR CLEANER ASSEMBLY................................................................................................1923 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................1925 REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................1925 INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.................................................................................1928 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................1931 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY...................................................................................1931 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY..................................................................................1933 POWER TRAIN.........................................................................................................................1935 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................1935 REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY................................................................................1935 INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...............................................................................1937 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................1939 DISASSEMBLE FINAL DRIVE ASSEMBLY............................................................................................1940 ASSEMBLE FINAL DRIVE ASSEMBLY...............................................................................................1945 REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY....................................................................1957 REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY.............................................................................1958 INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................................1960 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................1964 DISASSEMBLE SWING MACHINERY ASSEMBLY........................................................................................1965 ASSEMBLE SWING MACHINERY ASSEMBLY...........................................................................................1971 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................1980 REMOVE SWING CIRCLE ASSEMBLY................................................................................................1980 INSTALL SWING CIRCLE ASSEMBLY...............................................................................................1980 UNDERCARRIAGE AND FRAME.............................................................................................................1982 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................1982 SEPARATE TRACK ASSEMBLY.....................................................................................................1982 INSTALL TRACK ASSEMBLY......................................................................................................1984 REMOVE AND INSTALL SPROCKET.....................................................................................................1988 REMOVE SPROCKET.............................................................................................................1988 INSTALL SPROCKET............................................................................................................1988 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................1990 REMOVE IDLER AND IDLER CUSHION ASSEMBLY.....................................................................................1990 INSTALL IDLER AND IDLER CUSHION ASSEMBLY....................................................................................1991 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................1992 DISASSEMBLE IDLER ASSEMBLY..................................................................................................1992 ASSEMBLE IDLER ASSEMBLY.....................................................................................................1994 DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY.................................................................................2001 DISASSEMBLE IDLER CUSHION ASSEMBLY..........................................................................................2002 ASSEMBLE IDLER CUSHION ASSEMBLY.............................................................................................2003 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2005 DISASSEMBLE TRACK ROLLER ASSEMBLY...........................................................................................2005 ASSEMBLE TRUCK ROLLER ASSEMBLY..............................................................................................2006 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY................................................................................2008 DISASSEMBLE CARRIER ROLLER ASSEMBLY.........................................................................................2008 ASSEMBLE CARRIER ROLLER ASSEMBLY............................................................................................2010 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2013 REMOVE REVOLVING FRAME ASSEMBLY.............................................................................................2014 INSTALL REVOLVING FRAME ASSEMBLY............................................................................................2017 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2020 REMOVE COUNTERWEIGHT ASSEMBLY...............................................................................................2020 INSTALL COUNTERWEIGHT ASSEMBLY..............................................................................................2021 HYDRAULIC SYSTEM....................................................................................................................2023 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2023 REMOVE CENTER SWIVEL JOINT ASSEMBLY.........................................................................................2024 INSTALL CENTER SWIVEL JOINT ASSEMBLY........................................................................................2027 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2031 DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY....................................................................................2031 ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY.......................................................................................2032 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2035 REMOVE HYDRAULIC TANK ASSEMBLY..............................................................................................2036 INSTALL HYDRAULIC TANK ASSEMBLY.............................................................................................2040 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2047 REMOVE MAIN PUMP ASSEMBLY...................................................................................................2048 INSTALL MAIN PUMP ASSEMBLY..................................................................................................2055 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2063 REMOVE CONTROL VALVE ASSEMBLY...............................................................................................2064 INSTALL CONTROL VALVE ASSEMBLY..............................................................................................2076 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2089 REPLACE PRESSURE COMPENSATION VALVE SEAL RING...............................................................................2089 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2092 DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...............................................................................2092 ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................................2092 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2095 DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY.......................................................................................2095 ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..........................................................................................2096 WORK EQUIPMENT......................................................................................................................2098 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2098 REMOVE WORK EQUIPMENT ASSEMBLY..............................................................................................2099 INSTALL WORK EQUIPMENT ASSEMBLY.............................................................................................2102 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2105 DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY................................................................................2106 ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................................2111 CAB RELATED PARTS...................................................................................................................2120 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY........................................................................................2120 REMOVE OPERATOR CAB ASSEMBLY................................................................................................2121 INSTALL OPERATOR CAB ASSEMBLY...............................................................................................2131 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2141 REMOVE OPERATOR CAB GLASS (ADHERED GLASS)...................................................................................2143 INSTALL OPERATOR CAB GLASS (ADHERED GLASS)..................................................................................2143 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2154 REMOVE FRONT WINDOW ASSEMBLY................................................................................................2154 INSTALL FRONT WINDOW ASSEMBLY...............................................................................................2157 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2163 REMOVE FLOOR FRAME ASSEMBLY.................................................................................................2164 INSTALL FLOOR FRAME ASSEMBLY................................................................................................2170 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2178 REMOVE AIR CONDITIONER UNIT ASSEMBLY........................................................................................2179 INSTALL AIR CONDITIONER UNIT ASSEMBLY.......................................................................................2187 REMOVE AND INSTALL OPERATOR SEAT................................................................................................2195 REMOVE OPERATOR SEAT........................................................................................................2195 INSTALL OPERATOR SEAT.......................................................................................................2196 REMOVE AND INSTALL SEATBELT.....................................................................................................2198 REMOVE SEATBELT.............................................................................................................2198 INSTALL SEATBELT............................................................................................................2199 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY........................................................................2200 REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY................................................................................2200 INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY...............................................................................2205 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2213 REMOVE FRONT WIPER ASSEMBLY.................................................................................................2213 INSTALL FRONT WIPER ASSEMBLY................................................................................................2218 ELECTRICAL SYSTEM...................................................................................................................2226 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2226 REMOVE ENGINE CONTROLLER ASSEMBLY...........................................................................................2226 INSTALL ENGINE CONTROLLER ASSEMBLY..........................................................................................2228 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2230 REMOVE PUMP CONTROLLER ASSEMBLY.............................................................................................2230 INSTALL PUMP CONTROLLER ASSEMBLY............................................................................................2232 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2236 REMOVE MACHINE MONITOR ASSEMBLY.............................................................................................2236 INSTALL MACHINE MONITOR ASSEMBLY............................................................................................2239 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2243 REMOVE PUMP SWASH PLATE SENSOR..............................................................................................2243 INSTALL PUMP SWASH PLATE SENSOR.............................................................................................2245 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................2248 REMOVE KOMTRAX TERMINAL ASSEMBLY............................................................................................2248 INSTALL KOMTRAX TERMINAL ASSEMBLY...........................................................................................2251 60 MAINTENANCE STANDARD.................................................................................................................2255 CONTENTS............................................................................................................................2256 ABBREVIATION LIST...................................................................................................................2257 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.......................................................................................2262 ENGINE AND COOLING SYSTEM...........................................................................................................2264 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2264 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2265 POWER TRAIN.........................................................................................................................2267 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2267 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2268 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2271 MAINTENANCE STANDARD OF SPROCKET................................................................................................2273 SPROCKET TOOTH PROFILE FULL-SCALE DRAWING.......................................................................................2274 UNDERCARRIAGE AND FRAME.............................................................................................................2275 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2275 MAINTENANCE STANDARD OF IDLER...................................................................................................2276 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2278 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2280 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2281 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2284 MAINTENANCE STANDARD OF SWAMP SHOE..............................................................................................2285 MAINTENANCE STANDARD OF ROAD LINER..............................................................................................2286 HYDRAULIC SYSTEM....................................................................................................................2287 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2287 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2288 MAINTENANCE STANDARD OF LS-EPC VALVE............................................................................................2290 MAINTENANCE STANDARD OF PC-EPC VALVE............................................................................................2291 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2292 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2294 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2297 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2307 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2310 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2313 MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE..................................................................2314 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................2315 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2316 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...................................................2318 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)....................................................2319 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2320 WORK EQUIPMENT......................................................................................................................2321 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2321 DIMENSIONS OF ARM...............................................................................................................2327 DIMENSIONS OF BUCKET............................................................................................................2329 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2331 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2332 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2333 80 OTHERS...............................................................................................................................2335 CONTENTS............................................................................................................................2336 ABBREVIATION........................................................................................................................2338 AIR CONDITIONER SYSTEM..............................................................................................................2343 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2343 LAYOUT DRAWING OF AIR CONDITIONER SYSTEM........................................................................................2344 SPECIFICATION OF AIR CONDITIONER................................................................................................2346 CONFIGURATION OF REFRIGERATION CYCLE............................................................................................2347 FUNCTION OF REFRIGERATION CYCLE.................................................................................................2348 SYSTEM DIAGRAM OF AIR CONDITIONER...................................................................................................2349 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2350 AIR CONDITIONER UNIT............................................................................................................2350 STRUCTURE OF AIR CONDITIONER UNIT...........................................................................................2351 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2352 COMPONENT PARTS OF AIR CONDITIONER UNIT.....................................................................................2353 AIR CONDITIONER CONTROLLER......................................................................................................2357 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2357 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2357 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER......................................................................2357 COMPRESSOR......................................................................................................................2359 STRUCTURE OF COMPRESSOR.....................................................................................................2359 SPECIFICATIONS OF COMPRESSOR................................................................................................2359 FUNCTION OF COMPRESSOR......................................................................................................2359 OPERATION OF COMPRESSOR.....................................................................................................2359 CONDENSER.......................................................................................................................2360 STRUCTURE OF CONDENSER......................................................................................................2360 SPECIFICATIONS OF CONDENSOR.................................................................................................2360 FUNCTION OF COMPRESSOR......................................................................................................2360 AIR CONDITIONER RELATED SENSORS.................................................................................................2362 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2362 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2362 STRUCTURE OF OUTSIDE TEMPERATURE SENSOR.....................................................................................2362 FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR..................................................................................2362 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER................................................................2363 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2365 TEST AIR LEAKAGE (DUCT CONNECTION)..................................................................................................2369 TEST AIR LEAKAGE (DUCT CONNECTION)..............................................................................................2369 TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION.....................................................................................2372 TEST VENT (MODE) CHANGEOVER.........................................................................................................2373 TEST VENT (MODE) CHANGEOVER.....................................................................................................2373 TEST FRESH/RECIRC AIR CHANGEOVER....................................................................................................2375 TEST FRESH/RECIRC AIR CHANGEOVER................................................................................................2375 TEST SUNLIGHT SENSOR................................................................................................................2376 TEST SUNLIGHT SENSOR............................................................................................................2376 TEST DUAL PRESSURE SWITCH...........................................................................................................2377 TEST DUAL PRESSURE SWITCH.......................................................................................................2377 TEST RELAY..........................................................................................................................2378 TEST RELAY......................................................................................................................2378 SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS..............................................................................2380 PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER...................................................................................2381 INFORMATION DESCRIBED IN TROUBLESHOOTING............................................................................................2382 FAILURE CODE [879AKA]...............................................................................................................2385 FAILURE CODE [879AKB]...............................................................................................................2387 FAILURE CODE [879BKA]...............................................................................................................2389 FAILURE CODE [879BKB]...............................................................................................................2392 FAILURE CODE [879CKA]...............................................................................................................2395 FAILURE CODE [879CKB]...............................................................................................................2397 FAILURE CODE [879DKZ]...............................................................................................................2399 FAILURE CODE [879EMC]...............................................................................................................2403 FAILURE CODE [879FMC]...............................................................................................................2405 FAILURE CODE [879GKX]...............................................................................................................2407 AIR CONDITIONER DOES NOT OPERATE....................................................................................................2410 DEFECTIVE COOLING...................................................................................................................2413 HEATER DOES NOT OPERATE.............................................................................................................2422 COOL AIR DOES NOT COME OUT..........................................................................................................2426 NO AIR COMES OUT OR AIR FLOW IS ABNORMAL............................................................................................2433 FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE............................................................................................2437 CONNECT SERVICE TOOL................................................................................................................2441 CONNECT SERVICE TOOL............................................................................................................2442 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING..............................................................2443 HANDLE COMPRESSOR OIL...............................................................................................................2445 REPLACE DESICCANT...................................................................................................................2447 90 CIRCUIT DIAGRAMS.....................................................................................................................2449 CONTENTS............................................................................................................................2450 ABBREVIATION LIST...................................................................................................................2451 HOW TO READ THE CODES FOR ELECTRIC CABLE............................................................................................2456 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2460 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2460 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................2465 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2467 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM........................................................................................2467 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (1/7)..........................................................2471 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (2/7)..........................................................2473 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (3/7)..........................................................2475 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (4/7)..........................................................2477 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (5/7)..........................................................2479 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (6/7)..........................................................2481 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:600001 to 601173) (7/7)..........................................................2483 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (1/7).............................................................2485 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (2/7).............................................................2487 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (3/7).............................................................2489 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (4/7).............................................................2491 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (5/7).............................................................2493 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (6/7).............................................................2495 ELECTRICAL CIRCUIT DIAGRAM (APPLICABLE MACHINE:601174 and up) (7/7).............................................................2497 CONNECTOR AND WIRING HARNESS CHART..................................................................................................2499 CONNECTOR AND WIRING HARNESS CHART (1/11).......................................................................................2501 CONNECTOR AND WIRING HARNESS CHART (2/11).......................................................................................2503 CONNECTOR AND WIRING HARNESS CHART (3/11).......................................................................................2505 CONNECTOR AND WIRING HARNESS CHART (4/11).......................................................................................2507 CONNECTOR AND WIRING HARNESS CHART (5/11).......................................................................................2509 CONNECTOR AND WIRING HARNESS CHART (6/11).......................................................................................2511 CONNECTOR AND WIRING HARNESS CHART (7/11).......................................................................................2513 CONNECTOR AND WIRING HARNESS CHART (8/11).......................................................................................2515 CONNECTOR AND WIRING HARNESS CHART (9/11).......................................................................................2517 CONNECTOR AND WIRING HARNESS CHART (10/11)......................................................................................2519 CONNECTOR AND WIRING HARNESS CHART (11/11)......................................................................................2521 INDEX....................................................................................................................................2523
DESCRIPTION:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C8 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 31/12/24
