Komatsu PC210-11,PC210LC-11 Hydraulic Excavator Shop Manual PDF

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Komatsu PC210-11,PC210LC-11 Hydraulic Excavator Shop Manual UENBM00360 – PDF DOWNLOAD

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Komatsu PC210-11,PC210LC-11 Hydraulic Excavator Shop Manual UENBM00360 – PDF DOWNLOAD

Language : English
Pages : 2654
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC210-11,PC210LC-11 Hydraulic Excavator Shop Manual UENBM00360 – PDF DOWNLOAD

SERIAL NUMBERS

• 500007 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
FOREWORD, SAFETY, BASIC INFORMATION . 21
HOW TO READ THE SHOP MANUAL . 21
SAFETY NOTICE FOR OPERATION . 23
PRECAUTIONS TO PREVENT FIRE . 31
ACTIONS IF FIRE OCCURS 33
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 34
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 35
PRECAUTIONS FOR DEF . 36
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 36
PRECAUTIONS FOR ADDING 36
PRECAUTIONS FOR STORING . 36
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 36
THE OTHER PRECAUTIONS . 36
STORE AdBlue/DEF 37
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 38
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 40
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 46
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 48
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 49
PRACTICAL USE OF KOMTRAX 50
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 52
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 53
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 55
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 59
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 65
HOW TO READ ELECTRICAL WIRE CODE 66
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 70
ABBREVIATION LIST . 73
STANDARD TIGHTENING TORQUE TABLE 78
CONVERSION TABLE 85
01 SPECIFICATIONS . 91
CONTENTS 92
SPECIFICATIONS 93
SPECIFICATION DRAWING . 93
SPECIFICATION DRAWING: PC210-11, PC210LC-11 . 93
WORKING RANGE DRAWINGS 94
WORKING RANGE: PC210-11, PC210LC-11 . 94
SPECIFICATIONS 95
SPECIFICATIONS: PC210-11, PC210LC-11 95
WEIGHT TABLE 98
WEIGHT TABLE: PC210-11, PC210LC-11 98
TABLE OF FUEL, COOLANT, AND LUBRICANTS 100
10 STRUCTURE AND FUNCTION . 101
CONTENTS 102
UREA SCR SYSTEM . 106
LAYOUT DRAWING OF UREA SCR SYSTEM . 107
UREA SCR SYSTEM DIAGRAM . 112
FUNCTION OF UREA SCR SYSTEM . 113
FUNCTION OF AdBlue/DEF SYSTEM . 113
INDUCEMENT STRATEGY . 115
COMPONENT PARTS OF UREA SCR SYSTEM 123
AdBlue/DEF MIXING TUBE 123
SCR ASSEMBLY 123
AdBlue/DEF TANK . 126
AdBlue/DEF PUMP . 128
AdBlue/DEF INJECTOR . 129
AdBlue/DEF HOSE . 130
AdBlue/DEF TANK HEATING VALVE . 131
BOOT-UP SYSTEM 132
LAYOUT DRAWING OF BOOT-UP SYSTEM 132
SYSTEM OPERATING LAMP SYSTEM 134
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 134
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 134
BATTERY DISCONNECT SWITCH . 135
FUNCTION OF BATTERY DISCONNECT SWITCH . 135
ENGINE SYSTEM . 136
LAYOUT DRAWING OF ENGINE SYSTEM . 136
SPECIFICATIONS OF ENGINE SYSTEM . 137
FUNCTION OF ENGINE SYSTEM . 137
ENGINE CONTROL SYSTEM . 138
ENGINE CONTROL SYSTEM DIAGRAM . 138
FUNCTION OF ENGINE CONTROL SYSTEM . 139
AUTO-DECELERATION SYSTEM 141
AUTO-DECELERATION SYSTEM DIAGRAM 141
FUNCTION OF AUTO-DECELERATION SYSTEM 141
OPERATION OF AUTO-DECELERATION SYSTEM . 142
ENGINE AUTOMATIC WARM-UP SYSTEM . 143
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 143
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 144
OVERHEAT PREVENTION SYSTEM 145
OVERHEAT PREVENTION SYSTEM DIAGRAM 145
FUNCTION OF OVERHEAT PREVENTION SYSTEM 146
TURBOCHARGER PROTECTION SYSTEM 148
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 148
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 149
AUTOMATIC IDLE STOP SYSTEM 150
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 150
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 150
COMPONENT PARTS OF ENGINE SYSTEM 153
KVGT 153
EGR SYSTEM 156
EGR VALVE . 158
EGR COOLER 160
KCCV SYSTEM . 161
KCCV VENTILATOR . 163
KDPF 165
COOLING SYSTEM 170
LAYOUT DRAWING OF COOLING SYSTEM 170
SPECIFICATIONS OF COOLING SYSTEM 171
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 172
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 172
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 173
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 174
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 174
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 174
COMPONENT PARTS OF COOLING SYSTEM . 176
FAN CLUTCH 176
CONTROL SYSTEM 177
LAYOUT DRAWING OF CONTROL SYSTEM 177
MACHINE MONITOR SYSTEM 180
MACHINE MONITOR SYSTEM DIAGRAM 180
KOMTRAX SYSTEM 181
KOMTRAX SYSTEM DIAGRAM 181
FUNCTION OF KOMTRAX SYSTEM 181
PPC LEVERS 182
LH PPC LEVER 182
RH PPC LEVER 183
AUTOMATIC GREASE SYSTEM . 184
OUTLINE OF AUTO GREASE SYSTEM . 184
COMPONENT PARTS OF CONTROL SYSTEM . 199
MACHINE MONITOR . 199
KOMTRAX TERMINAL 212
PUMP CONTROLLER . 214
RESISTOR FOR PC-EPC VALVE . 218
CAN TERMINATING RESISTOR 219
PPC OIL PRESSURE SWITCH . 219
ENGINE CONTROLLER . 221
FUEL CONTROL DIAL . 227
228
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 228
FUNCTION OF ENGINE OIL PRESSURE SWITCH 229
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 229
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 230
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 230
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 230
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 230
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 230
STRUCTURE OF OVERLOAD CAUTION SENSOR 230
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 231
FUNCTION OF OVERLOAD CAUTION SENSOR . 231
HYDRAULIC SYSTEM 232
LAYOUT DRAWING OF HYDRAULIC SYSTEM 232
CLSS 238
STRUCTURE OF CLSS . 238
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 240
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 241
PRESSURE COMPENSATION CONTROL . 254
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 256
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 256
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 257
PUMP AND VALVE CONTROL SYSTEM . 262
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 262
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 263
COMPONENT PARTS OF HYDRAULIC SYSTEM . 265
HYDRAULIC TANK 265
MAIN PUMP . 266
PILOT OIL FILTER 293
CONTROL VALVE . 293
WORK EQUIPMENT SYSTEM . 350
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 350
STRUCTURE OF VALVE CONTROL 355
ONE-TOUCH POWER MAXIMIZING SYSTEM . 357
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 357
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 358
PPC LOCK SYSTEM . 359
PPC LOCK SYSTEM DIAGRAM . 359
FUNCTION OF PPC LOCK SYSTEM . 359
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 360
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 360
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 360
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 361
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 362
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 362
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 364
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 365
WORK EQUIPMENT AND SWING PPC VALVE 365
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 370
SOLENOID VALVE 376
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 379
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 381
ATT EPC VALVE ASSEMBLY 384
RETURN OIL FILTER . 385
QUICK COUPLER CONTROL VALVE . 387
PILOT CIRCUIT ACCUMULATOR . 389
ATTACHMENT CIRCUIT ACCUMULATOR 390
SWING SYSTEM 391
LAYOUT DRAWING OF SWING SYSTEM 391
SWING CONTROL SYSTEM DIAGRAM 395
FUNCTION OF SWING CONTROL SYSTEM 395
COMPONENT PARTS OF SWING SYSTEM . 399
SWING MOTOR . 399
SWING MACHINERY . 410
SWING CIRCLE 411
TRAVEL SYSTEM . 413
LAYOUT DRAWING OF TRAVEL SYSTEM . 413
TRAVEL CONTROL SYSTEM DIAGRAM . 417
FUNCTION OF TRAVEL CONTROL SYSTEM . 417
COMPONENT PARTS OF TRAVEL SYSTEM 419
TRAVEL MOTOR 419
FINAL DRIVE . 432
TRAVEL PPC VALVE 433
CENTER SWIVEL JOINT . 438
UNDERCARRIAGE AND FRAME . 440
LAYOUT DRAWING OF UNDERCARRIAGE . 440
SPECIFICATIONS OF UNDERCARRIAGE . 441
WORK EQUIPMENT 442
STRUCTURE OF WORK EQUIPMENT . 442
FUNCTION OF WORK EQUIPMENT 443
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 444
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 444
BUCKET CLEARANCE ADJUSTMENT SHIM 445
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 445
CAB AND ITS ATTACHMENTS . 446
ROPS CAB 446
STRUCTURE OF ROPS CAB . 446
FUNCTION OF ROPS CAB 446
CAB MOUNT . 447
STRUCTURE OF CAB MOUNT 447
FUNCTION OF CAB MOUNT . 447
CAB TIPPING STOPPER . 448
STRUCTURE OF CAB TIPPING STOPPER 448
FUNCTION OF CAB TIPPING STOPPER . 448
20 STANDARD VALUE TABLE . 449
CONTENTS 450
STANDARD VALUE TABLE FOR ENGINE . 451
STANDARD VALUE TABLE FOR ENGINE: PC210-11, PC210LC-11 . 451
STANDARD VALUE TABLE FOR MACHINE 455
STANDARD VALUE TABLE FOR MACHINE: PC210-11, PC210LC-11 455
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 468
STANDARD VALUE TABLE FOR ELECTRICAL . 472
STANDARD VALUE TABLE FOR ELECTRICAL . 472
30 TESTING AND ADJUSTING 483
CONTENTS 484
RELATED INFORMATION ON TESTING AND ADJUSTING 487
TOOLS FOR TESTING AND ADJUSTING . 487
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 493
ENGINE AND COOLING SYSTEM . 494
TEST ENGINE SPEED . 494
METHOD FOR TESTING ENGINE SPEED . 494
TEST BOOST PRESSURE . 497
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 497
METHOD FOR TESTING BOOST PRESSURE . 498
TEST EXHAUST GAS COLOR 499
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 499
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 500
TEST AND ADJUST VALVE CLEARANCE . 502
METHOD FOR TESTING VALVE CLEARANCE 502
METHOD FOR ADJUSTING VALVE CLEARANCE 503
TEST COMPRESSION PRESSURE . 504
METHOD FOR TESTING COMPRESSION PRESSURE . 504
TEST BLOWBY PRESSURE 509
METHOD FOR TESTING BLOWBY PRESSURE 509
TEST ENGINE OIL PRESSURE 511
METHOD FOR TESTING ENGINE OIL PRESSURE 511
TEST EGR VALVE AND KVGT OIL PRESSURE 512
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 512
TEST FUEL PRESSURE 514
METHOD FOR TESTING FUEL PRESSURE 515
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 520
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 521
BLEEDING AIR FROM FUEL SYSTEM . 526
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 526
TEST FUEL CIRCUIT FOR LEAKAGE . 527
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 527
HANDLE CYLINDER CUT-OUT MODE OPERATION 529
HANDLE NO-INJECTION CRANKING OPERATION 530
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 531
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 531
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 531
REPLACING FAN BELT 533
METHOD FOR REPLACING FAN BELT . 533
TEST COOLING FAN SPEED 534
METHOD FOR TESTING COOLING FAN SPEED 534
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 535
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 535
TEST SCR RELATED FUNCTIONS 536
TEST AdBlue/DEF PUMP RAISED PRESSURE 539
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 541
TEST AdBlue/DEF LINE HEATER RELAY 1 . 544
TEST AdBlue/DEF LINE HEATER RELAY 2 . 547
TEST AdBlue/DEF PUMP HEATER RELAY . 549
TEST AdBlue/DEF TANK HEATER VALVE . 552
TEST DENITRATION EFFICIENCY OF SCR 555
CLEAN AdBlue/DEF TANK . 558
METHOD FOR CLEANING AdBlue/DEF TANK . 558
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 562
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 562
POWER TRAIN . 564
TEST SWING CIRCLE BEARING CLEARANCE . 564
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 564
UNDERCARRIAGE AND FRAME . 565
TEST AND ADJUST TRACK TENSION . 565
METHOD FOR TESTING TRACK TENSION 565
METHOD FOR ADJUSTING TRACK TENSION 565
HYDRAULIC SYSTEM 567
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 567
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 567
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 568
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 569
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 575
TEST OIL PRESSURE OF CONTROL CIRCUIT 578
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 578
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 580
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 580
TEST PC-EPC VALVE OUTLET PRESSURE . 581
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 582
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 583
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 583
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 584
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 587
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 588
METHOD FOR ADJUSTING LS VALVE . 589
TEST OUTLET PRESSURE OF SOLENOID VALVE 590
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 590
OPERATING CONDITION OF SOLENOID VALVE . 591
TEST PPC VALVE OUTLET PRESSURE 594
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 594
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 596
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 596
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 597
TEST PUMP SWASH PLATE SENSOR 599
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 599
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 600
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 600
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 600
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 601
TEST OIL LEAKAGE 602
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 602
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 602
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 603
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 603
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 603
BLEED AIR FROM HYDRAULIC CIRCUIT 605
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 606
CAB AND ITS ATTACHMENTS . 608
TEST CAB TIPPING STOPPER 608
METHOD FOR TESTING CAB TIPPING STOPPER 608
METHOD FOR ADJUSTING MIRRORS 609
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 609
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 610
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 611
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 612
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 613
ELECTRICAL SYSTEM . 615
ELECTRICAL SYSTEM . 616
SET AND OPERATE MACHINE MONITOR . 616
OPERATOR MODE . 619
SERVICE MODE 624
METHOD FOR STARTING UP KOMTRAX TERMINAL . 697
ADJUST REARVIEW CAMERA ANGLE 702
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 702
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 705
HANDLE BATTERY DISCONNECT SWITCH 706
TEST DIODES . 707
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 707
METHOD FOR TESTING DIODE USING ANALOG TESTER 707
Pm CLINIC . 708
Pm CLINIC SERVICE . 708
Pm CLINIC CHECK SHEET . 712
40 TROUBLESHOOTING 723
CONTENTS 724
RELATED INFORMATION ON TROUBLESHOOTING 735
GENERAL TROUBLESHOOTING POINTS 735
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 736
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 748
CHECKS BEFORE TROUBLESHOOTING . 750
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 752
WALK-AROUND CHECK . 752
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 754
CHECK FUEL LEVEL AND TYPE . 754
CHECK IMPURE INGREDIENT IN FUEL . 754
CHECK FUEL PREFILTER 755
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 755
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 756
CHECK MAIN FILTER . 757
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 759
CHECK COOLANT LEVEL (RESERVOIR TANK) 760
CHECK CLOGGING OF AIR CLEANER . 760
OUTER ELEMENT – CLEAN . 761
ELEMENTS – REPLACE 763
CHECK HYDRAULIC OIL LEVEL . 764
CHECK HYDRAULIC OIL STRAINER 765
CHECK HYDRAULIC FILTER 766
CHECK OIL LEVEL IN SWING MACHINERY CASE . 767
CHECK OIL LEVEL IN DAMPER CASE 767
CHECK OIL LEVEL IN FINAL DRIVE CASE . 768
BLEED AIR FROM FUEL SYSTEM 768
BLEED AIR FROM HYDRAULIC SYSTEM . 768
ELECTRICAL EQUIPMENT – CHECK METHOD . 769
AUTOMATIC GREASE SYSTEM . 776
FINDING MALFUNCTIONS 776
MALFUNCTION FINDING PROCEDURES 778
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 780
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 790
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 793
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 797
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 799
CONNECTOR LIST AND LAYOUT . 802
CONNECTOR CONTACT IDENTIFICATION 815
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 855
FUSE LOCATION TABLE . 861
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 864
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 868
FAILURE CODES TABLE . 870
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 887
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit . 887
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 888
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit . 889
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 891
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit . 893
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 894
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit . 895
FAILURE CODE [879EMC] Ventilation Damper Malfunction 897
FAILURE CODE [879FMC] Air Mix Damper Malfunction 898
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 899
FAILURE CODE [989L00] Engine Controller Lock Caution 1 901
FAILURE CODE [989M00] Engine Controller Lock Caution 2 902
FAILURE CODE [989N00] Engine Controller Lock Caution 3 903
FAILURE CODE [A1U0N3] HC Desorb Request 1 . 904
FAILURE CODE [A1U0N4] HC Desorb Request 2 . 906
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3 908
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1 909
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 910
FAILURE CODE [AA10NX] Air Cleaner Clogging 911
FAILURE CODE [AB00KE] Charge Voltage Low 913
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) . 916
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) 918
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) 920
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) . 921
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) . 922
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) . 923
FAILURE CODE [AS00R6] Temporary Recovery of Inducement 924
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5 925
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning 926
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning 927
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution 928
FAILURE CODE [B@BAZG] Engine Oil Pressure Low . 929
FAILURE CODE [B@BAZK] Eng Oil Level Low . 930
FAILURE CODE [B@BCNS] Eng Water Overheat 932
FAILURE CODE [B@BCZK] Eng Water Level Low . 933
FAILURE CODE [B@HANS] Hyd Oil Overheat 935
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error 936
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error 937
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error . 939
FAILURE CODE [CA131] Throttle Sensor High Error . 941
FAILURE CODE [CA132] Throttle Sensor Low Error 943
FAILURE CODE [CA144] Coolant Temperature Sensor High Error 945
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error . 947
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error . 949
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 952
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error 954
FAILURE CODE [CA221] Ambient Pressure Sensor High Error . 956
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error 958
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error . 960
FAILURE CODE [CA234] Engine Overspeed . 961
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error . 962
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error 964
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error . 966
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error 968
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error . 970
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error 972
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error 974
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error 976
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error 978
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error 980
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error 982
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error 984
FAILURE CODE [CA343] Engine Controller Internal Failure . 986
FAILURE CODE [CA351] Injectors Drive Circuit Error 987
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error 988
FAILURE CODE [CA356] MAF Sensor High Error 991
FAILURE CODE [CA357] MAF Sensor Low Error . 993
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error . 995
FAILURE CODE [CA428] Water in Fuel Sensor High Error 996
FAILURE CODE [CA429] Water in Fuel Sensor Low Error . 998
FAILURE CODE [CA435] Engine Oil Pressure SW Error .1000
FAILURE CODE [CA441] Battery Voltage Low Error 1002
FAILURE CODE [CA442] Battery Voltage High Error .1004
FAILURE CODE [CA449] Common Rail Pressure High Error 2 1005
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error .1006
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error 1008
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate 1010
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error 1011
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error .1013
FAILURE CODE [CA553] Common Rail Pressure High Error 1 1015
FAILURE CODE [CA555] Crankcase Pressure High Error 1 1016
FAILURE CODE [CA556] Crankcase Pressure High Error 2 1017
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .1018
FAILURE CODE [CA595] Turbocharger Speed High Error 2 1021
FAILURE CODE [CA687] Turbocharger Speed Low Error .1022
FAILURE CODE [CA689] Engine NE Speed Sensor Error .1024
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error .1027
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error 1029
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error .1031
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error 1032
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error .1033
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .1035
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error .1040
FAILURE CODE [CA1664] KDOC Abnormality 1041
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error 1043
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 1044
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .1045
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error 1046
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error .1047
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error 1049
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error .1051
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error 1053
FAILURE CODE [CA1691] Defective Regeneration 1054
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error 1057
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error 1060
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error .1061
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .1063
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error .1066
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error 1068
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error 1069
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error 1070
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .1073
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error 1076
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error .1078
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error 1081
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error .1083
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error 1085
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error .1088
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .1090
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 .1092
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 .1095
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error 1100
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error 1101
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .1104
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error 1105
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 1107
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error 1108
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error .1111
FAILURE CODE [CA2288] Turbocharger Speed High Error 1 .1114
FAILURE CODE [CA2311] lMV Solenoid Error 1115
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error .1116
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error 1119
FAILURE CODE [CA2357] EGR Valve Servo Error .1121
FAILURE CODE [CA2381] KVGT Position Sensor High Error .1122
FAILURE CODE [CA2382] KVGT Position Sensor Low Error 1125
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error 1128
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .1131
FAILURE CODE [CA2387] KVGT Servo Error 1133
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error 1134
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .1137
FAILURE CODE [CA2637] KDOC Face Plugging 1140
FAILURE CODE [CA2639] Manual Stationary Regeneration Request 1142
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error 1145
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable 1151
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error .1154
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error 1156
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error .1159
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error 1161
FAILURE CODE [CA3142] SCR Temperature Sensor High Error .1164
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error 1165
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error .1166
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error 1168
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error .1169
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error 1170
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2 .1172
FAILURE CODE [CA3165] SCR Outlet Temperature High Error .1178
FAILURE CODE [CA3229] SCR Temperature High Error 1180
FAILURE CODE [CA3231] SCR Temperature High Error – Non Regeneration .1182
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error 1184
FAILURE CODE [CA3235] SCR Outlet Temperature High Error – Non Regeneration 1188
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error .1190
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error 1193
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .1196
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error .1199
FAILURE CODE [CA3253] KDOC Temperature Error – Non Regeneration .1201
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1 1204
FAILURE CODE [CA3255] KDPF Temperature Error – Non Regeneration .1207
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 1211
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 1213
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 1215
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error .1218
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error 1220
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error 1221
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error 1223
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error .1225
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .1226
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .1228
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error 1229
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error .1231
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error 1233
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error .1235
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1 1237
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 1238
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) 1239
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error 1245
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 1247
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error 1248
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error .1250
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error 1252
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error .1254
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error .1257
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction .1260
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error 1264
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error .1266
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error 1268
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error .1270
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error .1272
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error 1274
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1 .1276
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error .1282
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error .1284
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error .1286
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error .1288
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error .1293
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error .1299
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error 1302
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error 1303
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error 1304
FAILURE CODE [CA3741] Rail Press Valve Trip Error .1307
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error 1308
FAILURE CODE [CA3751] SCR Catalyst Degradation Error 1310
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .1312
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 1314
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 1317
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error .1320
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error 1324
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error .1326
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error 1330
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error 1332
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error .1334
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error 1336
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error 1339
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error .1341
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error .1343
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error .1347
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error .1351
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error 1354
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction 1357
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error .1359
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error .1360
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error .1361
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error 1364
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error .1367
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error .1369
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error 1371
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error .1373
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .1375
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error 1378
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error .1380
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .1383
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .1385
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error 1387
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error 1390
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .1393
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error .1396
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error 1399
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error .1402
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error .1405
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error .1409
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error .1410
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error 1411
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error .1412
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible .1414
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error .1417
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) .1420
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error 1422
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error .1425
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error 1427
FAILURE CODE [CA5383] Ash Accumulation High Error .1429
FAILURE CODE [D110KB] Battery Relay Output Short Circuit 1431
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit .1433
FAILURE CODE [D811MC] KOMTRAX Malfunction .1436
FAILURE CODE [D862KA] GPS Antenna Open Circuit 1437
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX) 1438
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .1440
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .1442
FAILURE CODE [DA20MC] Pump Controller Malfunction .1444
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error 1445
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error .1448
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller) .1451
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller) 1453
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) .1455
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller) .1457
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller) .1460
FAILURE CODE [DAF0MB] Monitor ROM Abnormality .1461
FAILURE CODE [DAF0MC] Monitor Malfunction .1462
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit .1463
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor) .1465
FAILURE CODE [DAFGMC] GPS Module Malfunction 1466
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) 1467
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) .1469
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) .1471
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) .1472
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU) .1473
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .1478
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .1483
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit 1488
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit .1490
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On 1492
FAILURE CODE [DFB1KZ] Service Lever Potentio 1 Open or Short Circuit 1494
FAILURE CODE [DFB2KZ] Service Lever Potentio 2 Open or Short Circuit 1497
FAILURE CODE [DFB3L8] Service Lever 1 Potentiometer Error .1500
FAILURE CODE [DFB4L8] Service Lever 2 Potentiometer Error .1502
FAILURE CODE [DFB5KZ] Service Lever Sub Potentio 1 Open or Short Circuit 1504
FAILURE CODE [DFB6KZ] Service Lever Sub Potentio 2 Open or Short Circuit 1507
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit .1510
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault .1512
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1514
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen 1516
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen 1518
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function .1520
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function 1523
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function .1526
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function 1529
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function .1532
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function .1535
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function 1538
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function .1541
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function 1544
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function 1547
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function 1550
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function .1553
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function 1556
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function .1559
FAILURE CODE [DHX1MA] Overload Sensor Abnormality (Analog) 1562
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function 1565
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function .1568
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit .1571
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit 1573
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit 1575
FAILURE CODE [DLM5KA] Fan Speed Sensor Open Circuit .1577
FAILURE CODE [DLM5MB] Fan control:Mismatch 1579
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range .1581
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range .1583
FAILURE CODE [DV20KB] Travel Alarm Short Circuit 1585
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit 1587
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit .1589
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit .1591
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit 1593
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit 1596
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit 1599
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit .1601
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit .1603
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit 1605
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit 1607
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit .1609
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit 1611
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit 1613
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit 1615
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit 1617
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .1619
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit 1621
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .1623
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit .1625
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit .1627
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit 1629
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit 1631
FAILURE CODE [DWN5KA] Fan Clutch Solenoid Open Circuit 1633
FAILURE CODE [DWN5KB] Fan Clutch Solenoid short Circuit .1635
FAILURE CODE [DWN5KY] Fan Clutch Solenoid Hot Short Circuit .1637
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit .1639
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit 1641
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit 1643
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit .1645
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit 1647
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit .1648
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit 1650
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit .1652
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit .1654
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit 1656
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit .1658
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit 1660
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit .1662
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit 1664
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit .1666
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit 1668
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit 1670
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit .1672
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit 1674
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit 1676
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit .1678
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit 1680
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit 1682
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit .1684
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit 1686
FAILURE CODE [DY20KA]Wiper Motor Open Circuit .1688
FAILURE CODE [DY20MA] Wiper Motor Defective Function 1690
FAILURE CODE [DY2CKB] Washer Motor Short Circuit 1692
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit .1695
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit 1697
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1699
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1699
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1705
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1708
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1710
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1712
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1715
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1716
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1717
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1718
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1719
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1720
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1721
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1722
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1723
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1724
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1725
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1726
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1728
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1729
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1730
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1731
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1733
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1734
E-24 FUNCTION SWITCH DOES NOT OPERATE .1735
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1736
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1737
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1738
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1739
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1740
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1741
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1742
E-32 ALARM BUZZER CANNOT BE CANCELED 1744
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1745
E-34 SERVICE MODE CANNOT BE SELECTED 1746
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1747
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1750
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1752
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1755
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1757
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1760
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1761
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1763
E-43 HORN DOES NOT SOUND 1764
E-44 HORN DOES NOT STOP SOUNDING 1767
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1769
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1770
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1772
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1773
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1774
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1775
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1776
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1777
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1778
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1779
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1780
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1781
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1783
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1784
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1785
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1785
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1786
FAILURE MODE AND CAUSE TABLE 1788
H-1 ANY OF WORK EQUIPMENT, SWING AND TRAVEL DOES NOT WORK .1800
H-2 ALL OF WORK EQUIPMENTS, SWING AND TRAVEL OPERATION LACK SPEED OR POWER 1801
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1804
H-4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP .1805
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1806
H-6 SPEED OR POWER OF BOOM IS LOW .1808
H-7 SPEED OR POWER OF ARM IS LOW 1812
H-8 SPEED OR POWER OF BUCKET IS LOW .1817
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1820
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1821
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1823
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1825
H-13 OTHER WORK EQUIPMENT MOVES WHEN ONE OF WORK EQUIPMENT IS RELIEVED 1826
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1827
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK 1828
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1829
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED 1830
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT , EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER .1831
H-19 TRAVEL SPEED DROPS LARGELY IN COMBINED OPERATION OF SWING AND TRAVE 1832
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1833
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1834
H-22 MACHINE IS HARD TO STEER OR TRAVEL POWER IS LOW 1836
H-23 TRAVEL SPEED IS LOW 1839
H-24 ONE OF TRACKS DOES NOT RUN .1841
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO LOW OR HIGH .1842
H-26 UPPER STRUCTURE DOES NOT SWING IN BOTH RIGHT AND LEFT DIRECTIONS .1843
H-27 UPPER STRUCTURE SWING IN ONLY ONE DIRECTION 1844
H-28 SWING ACCELERATION OR SWING SPEED OF UPPER STRUCTURE IS LOW IN BOTH RIGHT AND LEFT DIRECTIONS 1845
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION .1846
H-30 OVERRUN OF UPPER STRUCTURE IS LARGE IN BOTH RIGHT AND LEFT DIRECTIONS 1847
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING IN ONLY ONE DIRECTION .1848
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1849
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1850
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1851
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1852
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1853
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1854
H-38 Quick coupler cylinder will not extend .1855
H-39 Quick coupler cylinder will not retract (but buzzer does not sound) 1857
H-40 Buzzer does not sound (but quick coupler cylinder does retract) 1859
H-41 Quick coupler cylinder extends and retracts slowly .1861
TROUBLESHOOTING OF ENGINE (S-MODE) 1862
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1862
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1863
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1864
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1865
S-4 ENGINE STARTABILITY IS POOR .1867
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1869
S-6 ENGINE STOPS DURING OPERATION .1871
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1873
S-8 ENGINE LACKS POWER 1874
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1876
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1878
S-11 OIL BECOMES CONTAMINATED QUICKLY .1879
S-12 FUEL CONSUMPTION IS EXCESSIVE 1880
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1881
S-14 OIL PRESSURE DROPS .1882
S-15 FUEL MIXES INTO ENGINE OIL .1884
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1885
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1886
S-18 UNUSUAL NOISE IS HEARD .1887
S-19 VIBRATION IS EXCESSIVE .1888
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1889
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1890
S-22 ACTIVE REGENERATION TAKES TIME .1892
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1893
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1894
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1896
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1897
50 DISASSEMBLY AND ASSEMBLY .1899
CONTENTS 1900
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1905
HOW TO READ THIS MANUAL .1905
COATING MATERIALS LIST 1907
SPECIAL TOOLS LIST 1912
SKETCHES OF SPECIAL TOOLS .1924
ENGINE AND COOLING SYSTEM .1930
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1930
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1930
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1933
REMOVE AND INSTALL INJECTOR ASSEMBLY 1936
METHOD FOR REMOVING INJECTOR ASSEMBLY .1936
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1941
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1949
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1950
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1959
REMOVE AND INSTALL EGR VALVE ASSEMBLY .1975
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1975
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1976
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1978
METHOD FOR REMOVING EGR COOLER ASSEMBLY .1978
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .1982
REMOVE AND INSTALL STARTER ASSEMBLY .1987
METHOD FOR REMOVING STARTER ASSEMBLY 1987
METHOD FOR INSTALLING STARTER ASSEMBLY 1988
REMOVE AND INSTALL ALTERNATOR BELT 1991
METHOD FOR REMOVING ALTERNATOR BELT .1991
METHOD FOR INSTALLING ALTERNATOR BELT .1993
REMOVE AND INSTALL RADIATOR ASSEMBLY 1995
METHOD FOR REMOVING RADIATOR ASSEMBLY .1995
METHOD FOR INSTALLING RADIATOR ASSEMBLY .1997
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2000
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2000
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2003
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2006
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2006
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2008
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2010
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2010
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2014
REMOVE AND INSTALL FAN 2018
METHOD FOR INSTALLING FAN .2018
METHOD FOR REMOVING FAN .2018
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2019
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2019
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2028
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2040
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2040
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2043
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2047
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2047
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2048
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2051
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2051
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2051
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2053
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2053
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2055
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2060
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2060
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2064
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2068
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2068
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2074
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2080
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2080
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2086
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2092
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2092
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2092
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2094
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2094
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2094
REMOVE AND INSTALL KDPF ASSEMBLY 2095
METHOD FOR REMOVING KDPF ASSEMBLY .2095
METHOD FOR INSTALLING KDPF ASSEMBLY .2097
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2099
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2100
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2103
REMOVE AND INSTALL SCR ASSEMBLY .2108
METHOD FOR REMOVING SCR ASSEMBLY 2108
METHOD FOR INSTALLING SCR ASSEMBLY 2110
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2112
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2112
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2118
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2124
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2124
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2132
REMOVE AND INSTALL KCCV ASSEMBLY 2140
METHOD FOR REMOVING KCCV ASSEMBLY .2140
METHOD FOR INSTALLING KCCV ASSEMBLY .2142
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2147
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2147
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2153
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2159
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2159
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2162
REMOVE AND INSTALL AdBlue/DEF PUMP 2165
METHOD FOR REMOVING AdBlue/DEF PUMP .2165
METHOD FOR INSTALLING AdBlue/DEF PUMP .2168
REMOVE AND INSTALL AdBlue/DEF HOSE 2171
METHOD FOR REMOVING AdBlue/DEF HOSE .2171
METHOD FOR INSTALLING AdBlue/DEF HOSE .2178
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2184
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2184
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2185
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2187
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2187
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2189
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2192
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2192
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2193
POWER TRAIN .2194
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2194
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2194
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2195
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2197
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2197
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2201
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2210
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2210
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2212
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2216
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2216
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2220
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2227
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2227
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2227
UNDERCARRIAGE AND FRAME .2229
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2229
METHOD FOR SEPARATING TRACK ASSEMBLY 2229
METHOD FOR INSTALLING TRACK ASSEMBLY 2231
REMOVE AND INSTALL SPROCKET .2234
METHOD FOR REMOVING SPROCKET 2234
METHOD FOR INSTALLING SPROCKET 2234
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2236
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2236
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2237
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2238
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2238
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2239
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2243
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2243
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2244
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2246
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2247
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2248
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2250
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2250
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2251
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2254
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2254
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2256
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2259
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2259
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2262
HYDRAULIC SYSTEM 2266
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2266
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2266
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2268
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2271
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2271
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2272
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2274
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2274
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2276
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2279
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2279
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2282
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2285
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2285
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2292
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2300
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2300
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2301
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2305
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2305
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2305
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2307
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2307
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2308
REMOVE AND INSTALL QUICK COUPLER VALVE 2310
WORK EQUIPMENT 2312
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2312
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2312
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2316
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2321
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2321
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2324
CAB AND ITS ATTACHMENTS .2330
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2330
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2330
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2336
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2343
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2345
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2345
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2355
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2355
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2358
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2364
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2364
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2371
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2378
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2378
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2383
REMOVE AND INSTALL OPERATOR’S SEAT 2389
METHOD FOR REMOVING OPERATOR’S SEAT .2389
METHOD FOR INSTALLING OPERATOR’S SEAT .2391
REMOVE AND INSTALL SEAT BELT 2394
METHOD FOR REMOVING SEAT BELT .2394
METHOD FOR INSTALLING SEAT BELT .2395
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2396
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2396
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2401
ELECTRICAL SYSTEM .2409
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2409
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2409
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2410
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2412
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2412
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2416
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2421
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2421
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2424
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2428
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2428
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2429
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2430
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2430
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2430
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2432
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2432
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2433
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2434
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2434
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2436
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2438
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2438
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2441
60 MAINTENANCE STANDARD .2445
CONTENTS 2446
ENGINE AND COOLING SYSTEM .2447
MAINTENANCE STANDARD OF ENGINE MOUNT 2447
MAINTENANCE STANDARD OF COOLING SYSTEM 2448
POWER TRAIN .2450
MAINTENANCE STANDARD OF SWING CIRCLE 2450
MAINTENANCE STANDARD OF SWING MACHINERY .2451
MAINTENANCE STANDARD OF FINAL DRIVE .2453
MAINTENANCE STANDARD OF SPROCKET 2455
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2456
UNDERCARRIAGE AND FRAME .2458
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2458
MAINTENANCE STANDARD OF IDLER .2460
MAINTENANCE STANDARD OF TRACK ROLLER 2462
MAINTENANCE STANDARD OF CARRIER ROLLER 2463
MAINTENANCE STANDARD OF TRACK SHOE 2464
MAINTENANCE STANDARD OF TRIPLE SHOE .2467
MAINTENANCE STANDARD OF SWAMP SHOE 2468
MAINTENANCE STANDARD OF ROAD LINER 2469
HYDRAULIC SYSTEM 2470
MAINTENANCE STANDARD OF HYDRAULIC TANK 2470
MAINTENANCE STANDARD OF MAIN PUMP .2471
MAINTENANCE STANDARD OF LS-EPC VALVE 2472
MAINTENANCE STANDARD OF PC-EPC VALVE 2473
MAINTENANCE STANDARD OF SWING MOTOR .2474
MAINTENANCE STANDARD OF TRAVEL MOTOR 2477
MAINTENANCE STANDARD OF CONTROL VALVE .2480
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2490
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2493
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2496
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2497
MAINTENANCE STANDARD OF SOLENOID VALVE 2499
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2500
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2502
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2503
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2504
WORK EQUIPMENT 2505
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2505
DIMENSION OF ARM 2510
DIMENSIONS OF BUCKET 2512
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2514
MAINTENANCE STANDARD OF ARM CYLINDER 2515
MAINTENANCE STANDARD OF BUCKET CYLINDER .2516
80 APPENDIX .2517
CONTENTS 2518
AIR CONDITIONER SYSTEM 2520
PRECAUTIONS FOR REFRIGERANT .2520
AIR CONDITIONER COMPONENT .2521
SPECIFICATIONS OF AIR CONDITIONER .2523
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2524
OUTLINE OF REFRIGERATION CYCLE 2525
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2527
AIR CONDITIONER UNIT 2527
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2527
FUNCTION OF AIR CONDITIONER UNIT 2529
COMPONENT PARTS OF AIR CONDITIONER UNIT .2531
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2532
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2532
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2532
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2532
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2533
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2533
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2533
FUNCTION OF DUAL PRESSURE SWITCH 2534
AIR CONDITIONER CONTROLLER 2535
STRUCTURE OF AIR CONDITIONER CONTROLLER .2535
COMPRESSOR 2536
STRUCTURE OF COMPRESSOR .2536
SPECIFICATIONS OF COMPRESSOR 2536
FUNCTION OF COMPRESSOR 2537
CONDENSER .2538
STRUCTURE OF CONDENSER 2538
SPECIFICATIONS OF CONDENSER .2538
FUNCTION OF CONDENSER .2538
SENSORS FOR AIR CONDITIONER SYSTEM 2540
STRUCTURE OF SUNLIGHT SENSOR 2540
FUNCTION OF SUNLIGHT SENSOR .2540
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2540
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2540
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2542
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2544
AIR CONDITIONER SYSTEM DIAGRAM 2546
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2547
FUNCTION OF AIR CONDITIONER CONTROLLER 2548
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2549
TESTING AIR LEAKAGE (DUCT) 2553
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2553
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2555
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2556
TEST VENT (MODE) CHANGEOVER .2557
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2557
TESTING FRESH/RECIRC AIR CHANGEOVER .2559
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2559
TEST SUNLIGHT SENSOR 2560
METHOD FOR TESTING SUNLIGHT SENSOR 2560
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2561
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2561
TEST RELAYS .2562
METHOD FOR TESTING RELAYS .2562
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2563
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2564
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2567
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit .2569
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 2570
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit .2571
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 2573
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit .2575
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 2576
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit .2577
FAILURE CODE [879EMC] Ventilation Damper Malfunction 2579
FAILURE CODE [879FMC] Air Mix Damper Malfunction 2580
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 2581
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2583
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2585
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2588
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2590
TROUBLESHOOTING USING GAUGE PRESSURE 2592
CONNECTION OF SERVICE TOOL 2595
METHOD FOR CONNECTING SERVICE TOOL 2595
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2597
HANDLE COMPRESSOR OIL .2599
METHOD FOR REPLACING DESICCANT 2601
90 CIRCUIT DIAGRAMS .2603
CONTENTS 2604
HYDRAULIC CIRCUIT DIAGRAM .2605
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2605
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2609
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2611
ELECTRICAL CIRCUIT DIAGRAM 2613
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2613
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2617
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2619
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2621
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2623
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2625
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2627
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2629
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2631
INDEX .2633

DESCRIPTION:

Komatsu PC210-11,PC210LC-11 Hydraulic Excavator Shop Manual UENBM00360 – PDF DOWNLOAD

SERIAL NUMBERS

• 500007 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
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.

G.B 29/12/24