Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU PC210LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06516-C1 – PDF DOWNLOAD
$38.95
KOMATSU PC210LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06516-C1 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU PC210LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06516-C1 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC210LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06516-C1 – PDF DOWNLOAD
Language : English
Pages : 2650
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC210LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06516-C1 – PDF DOWNLOAD
COVER .................................................................................................................................. 1 00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 21 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 26 HOW TO READ THE SHOP MANUAL..................................................................................................... 26 SAFETY NOTICE FOR OPERATION..................................................................................................... 28 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 36 ACTIONS IF FIRE OCCURS.......................................................................................................... 38 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.................................................................................... 39 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................... 40 PRECAUTIONS FOR DEF............................................................................................................. 41 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.............................................................................. 41 PRECAUTIONS FOR ADDING...................................................................................................... 41 PRECAUTIONS FOR STORING..................................................................................................... 41 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE..................................................................................... 41 THE OTHER PRECAUTIONS....................................................................................................... 41 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 42 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS......................................................................... 45 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................... 51 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 53 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 54 PRACTICAL USE OF KOMTRAX........................................................................................................ 55 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 56 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 56 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 57 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 58 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 60 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 64 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 65 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 68 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 70 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 71 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 75 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 78 CONVERSION TABLE................................................................................................................ 85 01 SPECIFICATIONS....................................................................................................................... 91 CONTENTS............................................................................................................................ 92 ABBREVIATION LIST................................................................................................................... 93 SPECIFICATIONS...................................................................................................................... 98 SPECIFICATION DRAWING........................................................................................................... 98 SPECIFICATION DRAWING: PC210LC-11........................................................................................... 98 WORKING RANGE DRAWINGS.......................................................................................................... 99 WORKING RANGE: PC210LC-11................................................................................................... 99 SPECIFICATIONS.................................................................................................................. 100 SPECIFICATIONS: PC210LC-11.................................................................................................. 100 WEIGHT TABLE.................................................................................................................... 103 WEIGHT TABLE: PC210LC-11.................................................................................................... 103 TABLE OF FUEL, COOLANT, AND LUBRICANTS.......................................................................................... 105 10 STRUCTURE AND FUNCTION............................................................................................................... 107 CONTENTS............................................................................................................................ 108 ABBREVIATION LIST................................................................................................................... 111 UREA SCR SYSTEM..................................................................................................................... 116 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................... 117 UREA SCR SYSTEM DIAGRAM......................................................................................................... 122 FUNCTION OF UREA SCR SYSTEM..................................................................................................... 123 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................... 123 INDUCEMENT STRATEGY......................................................................................................... 125 COMPONENT PARTS OF UREA SCR SYSTEM.............................................................................................. 140 AdBlue/DEF MIXING TUBE...................................................................................................... 140 SCR ASSEMBLY................................................................................................................ 141 AdBlue/DEF TANK............................................................................................................. 143 AdBlue/DEF PUMP............................................................................................................. 145 AdBlue/DEF INJECTOR......................................................................................................... 146 AdBlue/DEF HOSE............................................................................................................. 147 AdBlue/DEF TANK HEATING VALVE............................................................................................... 148 BOOT-UP SYSTEM...................................................................................................................... 149 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 149 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 151 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 151 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 151 BATTERY DISCONNECT SWITCH....................................................................................................... 152 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 152 ENGINE SYSTEM....................................................................................................................... 153 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 153 SPECIFICATIONS OF ENGINE SYSTEM............................................................................................. 154 FUNCTION OF ENGINE SYSTEM................................................................................................... 154 ENGINE CONTROL SYSTEM........................................................................................................... 155 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................... 155 FUNCTION OF ENGINE CONTROL SYSTEM........................................................................................... 156 AUTO-DECELERATION SYSTEM........................................................................................................ 158 AUTO-DECELERATION SYSTEM DIAGRAM............................................................................................ 158 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 158 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 159 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 160 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM..................................................................................... 160 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 161 OVERHEAT PREVENTION SYSTEM...................................................................................................... 162 OVERHEAT PREVENTION SYSTEM DIAGRAM.......................................................................................... 162 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 163 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 165 TURBOCHARGER PROTECTION SYSTEM DIAGRAM...................................................................................... 165 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 166 AUTOMATIC IDLE STOP SYSTEM...................................................................................................... 167 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.......................................................................................... 167 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...................................................................................... 167 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................ 170 VGT......................................................................................................................... 170 EGR SYSTEM.................................................................................................................. 174 EGR VALVE................................................................................................................... 177 EGR COOLER.................................................................................................................. 179 KCCV SYSTEM................................................................................................................. 181 KCCV VENTILATOR............................................................................................................. 183 KDPF........................................................................................................................ 185 COOLING SYSTEM...................................................................................................................... 189 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 189 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 190 FAN SPEED CONTROL SYSTEM OF FAN CLUTCH.......................................................................................... 191 FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH.............................................................................. 191 FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH.......................................................................... 192 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH...................................................................................... 193 ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH.......................................................................... 193 FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH...................................................................... 193 COMPONENT PARTS OF COOLING SYSTEM............................................................................................... 195 FAN CLUTCH.................................................................................................................. 195 CONTROL SYSTEM...................................................................................................................... 196 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................ 196 MACHINE MONITOR SYSTEM.......................................................................................................... 199 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 199 KOMTRAX SYSTEM.................................................................................................................. 200 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 200 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 200 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................... 201 MACHINE MONITOR............................................................................................................. 201 KOMTRAX TERMINAL............................................................................................................ 216 PUMP CONTROLLER............................................................................................................. 218 RESISTOR FOR PC-EPC VALVE................................................................................................... 222 CAN TERMINATING RESISTOR.................................................................................................... 223 ENGINE CONTROLLER........................................................................................................... 224 FUEL CONTROL DIAL........................................................................................................... 231 HYDRAULIC SYSTEM.................................................................................................................... 233 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 233 CLSS............................................................................................................................ 239 STRUCTURE OF CLSS........................................................................................................... 239 OPERATION OF UNLOAD VALVE AND LS PRESSURE................................................................................... 241 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL................................................................................... 242 PRESSURE COMPENSATION CONTROL............................................................................................... 256 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 259 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 259 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 260 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 265 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 265 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 266 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 268 HYDRAULIC TANK.............................................................................................................. 268 MAIN PUMP................................................................................................................... 270 CONTROL VALVE............................................................................................................... 297 WORK EQUIPMENT SYSTEM............................................................................................................... 354 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 354 STRUCTURE OF VALVE CONTROL...................................................................................................... 359 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 361 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 361 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 362 PPC LOCK SYSTEM................................................................................................................. 363 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 363 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 363 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................. 364 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM..................................................................... 364 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................. 364 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 365 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................................... 366 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................. 366 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................... 367 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM........................................................................................ 368 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 368 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 374 2ND-LINE ATTACHMENT PPC VALVE............................................................................................... 381 SOLENOID VALVE.............................................................................................................. 383 ANTI-DROP VALVE FOR BOOM.................................................................................................... 386 ANTI-DROP VALVE FOR ARM..................................................................................................... 390 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)....................................................................... 395 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)........................................................................ 397 PILOT CIRCUIT ACCUMULATOR................................................................................................... 399 ATTACHMENT CIRCUIT ACCUMULATOR.............................................................................................. 400 SWING SYSTEM........................................................................................................................ 401 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 401 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 405 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 405 COMPONENT PARTS OF SWING SYSTEM................................................................................................. 409 SWING MOTOR................................................................................................................. 409 SWING MACHINERY............................................................................................................. 421 SWING CIRCLE................................................................................................................ 423 TRAVEL SYSTEM....................................................................................................................... 424 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 424 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 428 FUNCTION OF TRAVEL CONTROL SYSTEM........................................................................................... 429 COMPONENT PARTS OF TRAVEL SYSTEM................................................................................................ 430 TRAVEL MOTOR................................................................................................................ 430 FINAL DRIVE................................................................................................................. 443 TRAVEL PPC VALVE............................................................................................................ 445 CENTER SWIVEL JOINT......................................................................................................... 449 UNDERCARRIAGE AND FRAME............................................................................................................. 451 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................. 451 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 452 WORK EQUIPMENT...................................................................................................................... 453 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 453 FUNCTION OF WORK EQUIPMENT...................................................................................................... 453 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 454 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 454 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 454 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 454 CAB AND ITS ATTACHMENTS............................................................................................................. 455 ROPS CAB........................................................................................................................ 455 STRUCTURE OF ROPS CAB....................................................................................................... 455 FUNCTION OF ROPS CAB........................................................................................................ 455 CAB MOUNT....................................................................................................................... 456 STRUCTURE OF CAB MOUNT...................................................................................................... 456 FUNCTION OF CAB MOUNT....................................................................................................... 456 CAB TIPPING STOPPER............................................................................................................. 457 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 457 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 457 20 STANDARD VALUE TABLE................................................................................................................. 459 CONTENTS............................................................................................................................ 460 ABBREVIATION LIST................................................................................................................... 461 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 466 STANDARD VALUE TABLE FOR ENGINE: PC210LC-11..................................................................................... 466 STANDARD VALUE TABLE FOR MACHINE.................................................................................................... 470 STANDARD VALUE TABLE FOR MACHINE: PC210LC-11.................................................................................... 470 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE......................................................................... 483 STANDARD VALUE TABLE FOR ELECTRICAL................................................................................................. 487 STANDARD VALUE TABLE FOR ELECTRICAL............................................................................................. 487 30 TESTING AND ADJUSTING................................................................................................................ 497 CONTENTS............................................................................................................................ 498 ABBREVIATION LIST................................................................................................................... 501 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 506 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 506 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 512 ENGINE AND COOLING SYSTEM........................................................................................................... 513 TEST ENGINE SPEED............................................................................................................... 513 METHOD FOR TESTING ENGINE SPEED............................................................................................. 513 TEST BOOST PRESSURE............................................................................................................. 516 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR........................................................................ 516 METHOD FOR TESTING BOOST PRESSURE........................................................................................... 517 TEST EXHAUST GAS COLOR.......................................................................................................... 518 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................. 518 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER......................................................................... 519 TEST AND ADJUST VALVE CLEARANCE................................................................................................. 521 METHOD FOR TESTING VALVE CLEARANCE.......................................................................................... 521 METHOD FOR ADJUSTING VALVE CLEARANCE........................................................................................ 522 TEST COMPRESSION PRESSURE....................................................................................................... 523 METHOD FOR TESTING COMPRESSION PRESSURE..................................................................................... 523 TEST BLOWBY PRESSURE............................................................................................................ 528 METHOD FOR TESTING BLOWBY PRESSURE.......................................................................................... 528 TEST ENGINE OIL PRESSURE........................................................................................................ 530 METHOD FOR TESTING ENGINE OIL PRESSURE...................................................................................... 530 TEST EGR VALVE AND VGT OIL PRESSURE............................................................................................. 531 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................... 531 TEST FUEL PRESSURE.............................................................................................................. 533 METHOD FOR TESTING FUEL PRESSURE............................................................................................ 534 TEST FUEL DISCHARGE, RETURN AND LEAKAGE......................................................................................... 539 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE....................................................................... 540 BLEEDING AIR FROM FUEL SYSTEM................................................................................................... 545 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM.................................................................................... 545 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................... 546 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................. 546 HANDLE CYLINDER CUT-OUT MODE OPERATION.......................................................................................... 548 HANDLE NO-INJECTION CRANKING OPERATION.......................................................................................... 549 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 550 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT......................................................................... 550 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT........................................................................ 550 TEST COOLING FAN SPEED.......................................................................................................... 552 METHOD FOR TESTING COOLING FAN SPEED........................................................................................ 552 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................................. 553 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 553 TEST SCR RELATED FUNCTIONS...................................................................................................... 554 TEST AdBlue/DEF PUMP RAISED PRESSURE........................................................................................ 557 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR.............................................................................. 560 TEST AdBlue/DEF LINE HEATER RELAY 1......................................................................................... 563 TEST AdBlue/DEF LINE HEATER RELAY 2......................................................................................... 566 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................... 569 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................... 572 TEST DENITRATION EFFICIENCY OF SCR.......................................................................................... 575 CLEAN AdBlue/DEF TANK........................................................................................................... 579 METHOD FOR CLEANING AdBlue/DEF TANK......................................................................................... 579 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................................................... 583 METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................................. 583 POWER TRAIN......................................................................................................................... 585 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................. 585 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE........................................................................... 585 UNDERCARRIAGE AND FRAME............................................................................................................. 586 TEST AND ADJUST TRACK TENSION................................................................................................... 586 METHOD FOR TESTING TRACK TENSION............................................................................................ 586 METHOD FOR ADJUSTING TRACK TENSION.......................................................................................... 586 HYDRAULIC SYSTEM.................................................................................................................... 588 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 588 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT.............................................................. 588 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...................................................... 589 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................... 590 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................. 596 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 599 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 599 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT......................................................................... 601 TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................................. 601 TEST PC-EPC VALVE OUTLET PRESSURE........................................................................................... 602 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT................................................................ 603 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT......................................................................... 604 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR.............................................................. 604 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL................................................................. 605 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................... 608 METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE............................................................................. 609 METHOD FOR ADJUSTING LS VALVE............................................................................................... 610 TEST OUTLET PRESSURE OF SOLENOID VALVE.......................................................................................... 611 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE........................................................................ 611 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 612 TEST PPC VALVE OUTLET PRESSURE.................................................................................................. 615 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE................................................................................ 615 ADJUST WORK EQUIPMENT AND SWING PPC VALVES...................................................................................... 617 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............................................................ 617 TEST PUMP SWASH PLATE SENSOR.................................................................................................... 618 METHOD FOR TESTING PUMP SWASH PLATE SENSOR.................................................................................. 618 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................................ 619 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER................................... 619 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER........................................................ 619 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE........................................................... 620 TEST OIL LEAKAGE................................................................................................................ 621 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER........................................................................... 621 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER............................................................................ 621 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER......................................................................... 622 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR............................................................................. 622 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR............................................................................ 622 BLEED AIR FROM HYDRAULIC CIRCUIT................................................................................................ 624 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.............................................................................. 626 CAB AND ITS ATTACHMENTS............................................................................................................. 628 TEST CAB TIPPING STOPPER........................................................................................................ 628 METHOD FOR TESTING CAB TIPPING STOPPER...................................................................................... 628 METHOD FOR ADJUSTING MIRRORS.................................................................................................... 629 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)....................................................................... 629 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)................................................... 630 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...................................................................... 631 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B).................................................. 632 PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)....................................................................... 633 ELECTRICAL SYSTEM................................................................................................................... 635 SET AND OPERATE MACHINE MONITOR................................................................................................. 635 OPERATOR MODE............................................................................................................... 638 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 639 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 639 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................... 640 CHECKING FUNCTION OF SERVICE METER.......................................................................................... 640 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD................................................................... 640 SERVICE MODE................................................................................................................ 643 METHOD FOR OPERATING SERVICE MODE........................................................................................... 643 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...................................................................... 645 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...................................................................... 651 ABNORMALITY RECORD MENU..................................................................................................... 662 METHOD FOR CONFIRMING MAINTENANCE RECORD.................................................................................... 666 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................... 667 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................. 671 DEFAULT MENU................................................................................................................ 672 DIAGNOSTIC TESTS MENU....................................................................................................... 679 ADJUSTMENT MENU............................................................................................................. 688 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................................. 706 KOMTRAX SETTINGS MENU....................................................................................................... 707 METHOD FOR DISPLAYING SERVICE MESSAGE....................................................................................... 710 METHOD FOR STARTING UP KOMTRAX TERMINAL......................................................................................... 712 ADJUST REARVIEW CAMERA ANGLE.................................................................................................... 717 METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE.................................................................................. 717 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 720 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 721 TEST DIODES..................................................................................................................... 722 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 722 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 722 Pm CLINIC........................................................................................................................... 723 Pm CLINIC SERVICE............................................................................................................... 723 Pm CLINIC CHECK SHEET....................................................................................................... 724 40 TROUBLESHOOTING...................................................................................................................... 735 CONTENTS............................................................................................................................ 736 ABBREVIATION LIST................................................................................................................... 746 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 751 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 751 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 752 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 764 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 766 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 768 WALK-AROUND CHECK........................................................................................................... 768 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 770 CHECK FUEL LEVEL AND TYPE................................................................................................... 770 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 770 CHECK FUEL PREFILTER........................................................................................................ 771 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 771 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................................... 772 CHECK MAIN FILTER........................................................................................................... 773 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 775 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 776 CHECK CLOGGING OF AIR CLEANER............................................................................................... 776 OUTER ELEMENT - CLEAN....................................................................................................... 777 ELEMENTS - REPLACE.......................................................................................................... 779 CHECK HYDRAULIC OIL LEVEL................................................................................................... 780 CHECK HYDRAULIC OIL STRAINER................................................................................................ 781 CHECK HYDRAULIC FILTER...................................................................................................... 782 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 783 CHECK OIL LEVEL IN DAMPER CASE.............................................................................................. 784 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 784 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 785 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 785 ELECTRICAL EQUIPMENT - CHECK METHOD......................................................................................... 785 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION................................................................................. 793 PROCEDURE FOR TESTING AND TROUBLESHOOTING....................................................................................... 803 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................. 806 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................................. 810 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................. 812 CONNECTOR LIST AND LAYOUT....................................................................................................... 815 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 828 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 868 FUSE LOCATION TABLE............................................................................................................. 874 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..................................................................... 876 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..................................... 880 FAILURE CODES TABLE............................................................................................................. 882 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................... 899 FAILURE CODE [879AKA]........................................................................................................... 899 FAILURE CODE [879AKB]........................................................................................................... 900 FAILURE CODE [879BKA]........................................................................................................... 901 FAILURE CODE [879BKB]........................................................................................................... 903 FAILURE CODE [879CKA]........................................................................................................... 905 FAILURE CODE [879CKB]........................................................................................................... 906 FAILURE CODE [879DKZ]........................................................................................................... 907 FAILURE CODE [879EMC]........................................................................................................... 909 FAILURE CODE [879FMC]........................................................................................................... 910 FAILURE CODE [879GKX]........................................................................................................... 911 FAILURE CODE [989L00]........................................................................................................... 913 FAILURE CODE [989M00]........................................................................................................... 914 FAILURE CODE [989N00]........................................................................................................... 915 FAILURE CODE [A1U0N3]........................................................................................................... 916 FAILURE CODE [A1U0N4]........................................................................................................... 918 FAILURE CODE [A900FR]........................................................................................................... 920 FAILURE CODE [A900N6]........................................................................................................... 921 FAILURE CODE [A900NY]........................................................................................................... 922 FAILURE CODE [AA10NX]........................................................................................................... 923 FAILURE CODE [AB00KE]........................................................................................................... 925 FAILURE CODE [AQ10N3]........................................................................................................... 928 FAILURE CODE [AS00N3]........................................................................................................... 930 FAILURE CODE [AS00R2]........................................................................................................... 932 FAILURE CODE [AS00R3]........................................................................................................... 933 FAILURE CODE [AS00R4]........................................................................................................... 934 FAILURE CODE [AS00R5]........................................................................................................... 935 FAILURE CODE [AS00R6]........................................................................................................... 936 FAILURE CODE [AS00ZK]........................................................................................................... 937 FAILURE CODE [AS10KM]........................................................................................................... 938 FAILURE CODE [AS10NR]........................................................................................................... 939 FAILURE CODE [AS10NT]........................................................................................................... 940 FAILURE CODE [B@BAZG]........................................................................................................... 941 FAILURE CODE [B@BAZK]........................................................................................................... 942 FAILURE CODE [B@BCNS]........................................................................................................... 944 FAILURE CODE [B@BCZK]........................................................................................................... 945 FAILURE CODE [B@HANS]........................................................................................................... 947 FAILURE CODE [CA115]............................................................................................................ 948 FAILURE CODE [CA122]............................................................................................................ 949 FAILURE CODE [CA123]............................................................................................................ 951 FAILURE CODE [CA131]............................................................................................................ 953 FAILURE CODE [CA132]............................................................................................................ 955 FAILURE CODE [CA144]............................................................................................................ 957 FAILURE CODE [CA145]............................................................................................................ 959 FAILURE CODE [CA153]............................................................................................................ 961 FAILURE CODE [CA154]............................................................................................................ 964 FAILURE CODE [CA187]............................................................................................................ 966 FAILURE CODE [CA221]............................................................................................................ 968 FAILURE CODE [CA222]............................................................................................................ 970 FAILURE CODE [CA227]............................................................................................................ 972 FAILURE CODE [CA234]............................................................................................................ 973 FAILURE CODE [CA238]............................................................................................................ 974 FAILURE CODE [CA239]............................................................................................................ 976 FAILURE CODE [CA249]............................................................................................................ 978 FAILURE CODE [CA256]............................................................................................................ 980 FAILURE CODE [CA271]............................................................................................................ 982 FAILURE CODE [CA272]............................................................................................................ 984 FAILURE CODE [CA322]............................................................................................................ 986 FAILURE CODE [CA323]............................................................................................................ 988 FAILURE CODE [CA324]............................................................................................................ 990 FAILURE CODE [CA325]............................................................................................................ 992 FAILURE CODE [CA331]............................................................................................................ 994 FAILURE CODE [CA332]............................................................................................................ 996 FAILURE CODE [CA343]............................................................................................................ 998 FAILURE CODE [CA351]............................................................................................................ 999 FAILURE CODE [CA352]............................................................................................................1000 FAILURE CODE [CA356]............................................................................................................1003 FAILURE CODE [CA357]............................................................................................................1005 FAILURE CODE [CA386]............................................................................................................1007 FAILURE CODE [CA428]............................................................................................................1008 FAILURE CODE [CA429]............................................................................................................1010 FAILURE CODE [CA435]............................................................................................................1012 FAILURE CODE [CA441]............................................................................................................1014 FAILURE CODE [CA442]............................................................................................................1016 FAILURE CODE [CA449]............................................................................................................1017 FAILURE CODE [CA451]............................................................................................................1018 FAILURE CODE [CA452]............................................................................................................1020 FAILURE CODE [CA488]............................................................................................................1022 FAILURE CODE [CA515]............................................................................................................1023 FAILURE CODE [CA516]............................................................................................................1025 FAILURE CODE [CA553]............................................................................................................1027 FAILURE CODE [CA555]............................................................................................................1028 FAILURE CODE [CA556]............................................................................................................1029 FAILURE CODE [CA559]............................................................................................................1030 FAILURE CODE [CA595]............................................................................................................1033 FAILURE CODE [CA687]............................................................................................................1034 FAILURE CODE [CA689]............................................................................................................1036 FAILURE CODE [CA691]............................................................................................................1039 FAILURE CODE [CA692]............................................................................................................1041 FAILURE CODE [CA697]............................................................................................................1043 FAILURE CODE [CA698]............................................................................................................1044 FAILURE CODE [CA731]............................................................................................................1045 FAILURE CODE [CA778]............................................................................................................1047 FAILURE CODE [CA1117]...........................................................................................................1052 FAILURE CODE [CA1664]...........................................................................................................1053 FAILURE CODE [CA1669]...........................................................................................................1055 FAILURE CODE [CA1673]...........................................................................................................1056 FAILURE CODE [CA1677]...........................................................................................................1057 FAILURE CODE [CA1678]...........................................................................................................1058 FAILURE CODE [CA1682]...........................................................................................................1059 FAILURE CODE [CA1683]...........................................................................................................1061 FAILURE CODE [CA1684]...........................................................................................................1063 FAILURE CODE [CA1686]...........................................................................................................1065 FAILURE CODE [CA1691]...........................................................................................................1066 FAILURE CODE [CA1694]...........................................................................................................1069 FAILURE CODE [CA1695]...........................................................................................................1072 FAILURE CODE [CA1696]...........................................................................................................1073 FAILURE CODE [CA1712]...........................................................................................................1075 FAILURE CODE [CA1713]...........................................................................................................1078 FAILURE CODE [CA1714]...........................................................................................................1080 FAILURE CODE [CA1715]...........................................................................................................1081 FAILURE CODE [CA1776]...........................................................................................................1082 FAILURE CODE [CA1777]...........................................................................................................1085 FAILURE CODE [CA1843]...........................................................................................................1088 FAILURE CODE [CA1844]...........................................................................................................1090 FAILURE CODE [CA1879]...........................................................................................................1093 FAILURE CODE [CA1881]...........................................................................................................1095 FAILURE CODE [CA1883]...........................................................................................................1097 FAILURE CODE [CA1885]...........................................................................................................1100 FAILURE CODE [CA1887]...........................................................................................................1102 FAILURE CODE [CA1921]...........................................................................................................1104 FAILURE CODE [CA1922]...........................................................................................................1107 FAILURE CODE [CA1942]...........................................................................................................1112 FAILURE CODE [CA1993]...........................................................................................................1113 FAILURE CODE [CA2185]...........................................................................................................1116 FAILURE CODE [CA2186]...........................................................................................................1117 FAILURE CODE [CA2249]...........................................................................................................1119 FAILURE CODE [CA2271]...........................................................................................................1120 FAILURE CODE [CA2272]...........................................................................................................1123 FAILURE CODE [CA2288]...........................................................................................................1126 FAILURE CODE [CA2311]...........................................................................................................1127 FAILURE CODE [CA2349]...........................................................................................................1128 FAILURE CODE [CA2353]...........................................................................................................1131 FAILURE CODE [CA2357]...........................................................................................................1133 FAILURE CODE [CA2381]...........................................................................................................1134 FAILURE CODE [CA2382]...........................................................................................................1137 FAILURE CODE [CA2383]...........................................................................................................1140 FAILURE CODE [CA2386]...........................................................................................................1143 FAILURE CODE [CA2387]...........................................................................................................1145 FAILURE CODE [CA2555]...........................................................................................................1146 FAILURE CODE [CA2556]...........................................................................................................1149 FAILURE CODE [CA2637]...........................................................................................................1152 FAILURE CODE [CA2639]...........................................................................................................1154 FAILURE CODE [CA2771]...........................................................................................................1157 FAILURE CODE [CA2777]...........................................................................................................1163 FAILURE CODE [CA2976]...........................................................................................................1166 FAILURE CODE [CA3133]...........................................................................................................1168 FAILURE CODE [CA3134]...........................................................................................................1171 FAILURE CODE [CA3135]...........................................................................................................1173 FAILURE CODE [CA3142]...........................................................................................................1176 FAILURE CODE [CA3143]...........................................................................................................1177 FAILURE CODE [CA3144]...........................................................................................................1178 FAILURE CODE [CA3146]...........................................................................................................1180 FAILURE CODE [CA3147]...........................................................................................................1181 FAILURE CODE [CA3148]...........................................................................................................1182 FAILURE CODE [CA3151]...........................................................................................................1184 FAILURE CODE [CA3165]...........................................................................................................1190 FAILURE CODE [CA3229]...........................................................................................................1192 FAILURE CODE [CA3231]...........................................................................................................1194 FAILURE CODE [CA3232]...........................................................................................................1196 FAILURE CODE [CA3235]...........................................................................................................1200 FAILURE CODE [CA3239]...........................................................................................................1202 FAILURE CODE [CA3241]...........................................................................................................1205 FAILURE CODE [CA3242]...........................................................................................................1208 FAILURE CODE [CA3251]...........................................................................................................1211 FAILURE CODE [CA3253]...........................................................................................................1213 FAILURE CODE [CA3254]...........................................................................................................1216 FAILURE CODE [CA3255]...........................................................................................................1219 FAILURE CODE [CA3256]...........................................................................................................1223 FAILURE CODE [CA3311]...........................................................................................................1225 FAILURE CODE [CA3312]...........................................................................................................1227 FAILURE CODE [CA3313]...........................................................................................................1230 FAILURE CODE [CA3314]...........................................................................................................1232 FAILURE CODE [CA3315]...........................................................................................................1233 FAILURE CODE [CA3316]...........................................................................................................1235 FAILURE CODE [CA3317]...........................................................................................................1237 FAILURE CODE [CA3318]...........................................................................................................1238 FAILURE CODE [CA3319]...........................................................................................................1240 FAILURE CODE [CA3321]...........................................................................................................1241 FAILURE CODE [CA3322]...........................................................................................................1243 FAILURE CODE [CA3419]...........................................................................................................1245 FAILURE CODE [CA3421]...........................................................................................................1247 FAILURE CODE [CA3497]...........................................................................................................1249 FAILURE CODE [CA3498]...........................................................................................................1250 FAILURE CODE [CA3543]...........................................................................................................1251 FAILURE CODE [CA3545]...........................................................................................................1257 FAILURE CODE [CA3547]...........................................................................................................1259 FAILURE CODE [CA3558]...........................................................................................................1260 FAILURE CODE [CA3559]...........................................................................................................1262 FAILURE CODE [CA3562]...........................................................................................................1264 FAILURE CODE [CA3563]...........................................................................................................1266 FAILURE CODE [CA3567]...........................................................................................................1269 FAILURE CODE [CA3568]...........................................................................................................1272 FAILURE CODE [CA3571]...........................................................................................................1276 FAILURE CODE [CA3572]...........................................................................................................1278 FAILURE CODE [CA3574]...........................................................................................................1280 FAILURE CODE [CA3575]...........................................................................................................1282 FAILURE CODE [CA3577]...........................................................................................................1284 FAILURE CODE [CA3578]...........................................................................................................1286 FAILURE CODE [CA3582]...........................................................................................................1288 FAILURE CODE [CA3583]...........................................................................................................1294 FAILURE CODE [CA3596]...........................................................................................................1296 FAILURE CODE [CA3649]...........................................................................................................1298 FAILURE CODE [CA3681]...........................................................................................................1300 FAILURE CODE [CA3682]...........................................................................................................1305 FAILURE CODE [CA3713]...........................................................................................................1311 FAILURE CODE [CA3717]...........................................................................................................1314 FAILURE CODE [CA3718]...........................................................................................................1315 FAILURE CODE [CA3725]...........................................................................................................1316 FAILURE CODE [CA3741]...........................................................................................................1319 FAILURE CODE [CA3748]...........................................................................................................1320 FAILURE CODE [CA3751]...........................................................................................................1322 FAILURE CODE [CA3755]...........................................................................................................1324 FAILURE CODE [CA3866]...........................................................................................................1326 FAILURE CODE [CA3867]...........................................................................................................1329 FAILURE CODE [CA3868]...........................................................................................................1332 FAILURE CODE [CA3899]...........................................................................................................1336 FAILURE CODE [CA3911]...........................................................................................................1338 FAILURE CODE [CA3912]...........................................................................................................1342 FAILURE CODE [CA3932]...........................................................................................................1344 FAILURE CODE [CA3933]...........................................................................................................1346 FAILURE CODE [CA3934]...........................................................................................................1348 FAILURE CODE [CA3935]...........................................................................................................1351 FAILURE CODE [CA3936]...........................................................................................................1353 FAILURE CODE [CA4151]...........................................................................................................1355 FAILURE CODE [CA4152]...........................................................................................................1359 FAILURE CODE [CA4155]...........................................................................................................1363 FAILURE CODE [CA4156]...........................................................................................................1365 FAILURE CODE [CA4157]...........................................................................................................1368 FAILURE CODE [CA4158]...........................................................................................................1370 FAILURE CODE [CA4159]...........................................................................................................1371 FAILURE CODE [CA4161]...........................................................................................................1372 FAILURE CODE [CA4162]...........................................................................................................1375 FAILURE CODE [CA4163]...........................................................................................................1378 FAILURE CODE [CA4164]...........................................................................................................1379 FAILURE CODE [CA4165]...........................................................................................................1381 FAILURE CODE [CA4166]...........................................................................................................1383 FAILURE CODE [CA4168]...........................................................................................................1384 FAILURE CODE [CA4169]...........................................................................................................1387 FAILURE CODE [CA4171]...........................................................................................................1389 FAILURE CODE [CA4249]...........................................................................................................1392 FAILURE CODE [CA4251]...........................................................................................................1394 FAILURE CODE [CA4259]...........................................................................................................1396 FAILURE CODE [CA4261]...........................................................................................................1399 FAILURE CODE [CA4277]...........................................................................................................1402 FAILURE CODE [CA4281]...........................................................................................................1405 FAILURE CODE [CA4459]...........................................................................................................1408 FAILURE CODE [CA4461]...........................................................................................................1411 FAILURE CODE [CA4658]...........................................................................................................1414 FAILURE CODE [CA4731]...........................................................................................................1418 FAILURE CODE [CA4732]...........................................................................................................1419 FAILURE CODE [CA4739]...........................................................................................................1420 FAILURE CODE [CA4768]...........................................................................................................1421 FAILURE CODE [CA4769]...........................................................................................................1423 FAILURE CODE [CA4842]...........................................................................................................1426 FAILURE CODE [CA4952]...........................................................................................................1429 FAILURE CODE [CA5115]...........................................................................................................1431 FAILURE CODE [CA5179]...........................................................................................................1434 FAILURE CODE [CA5181]...........................................................................................................1436 FAILURE CODE [CA5383]...........................................................................................................1438 FAILURE CODE [D110KB]...........................................................................................................1440 FAILURE CODE [D19JKZ]...........................................................................................................1442 FAILURE CODE [D811MC]...........................................................................................................1445 FAILURE CODE [D862KA]...........................................................................................................1446 FAILURE CODE [D8ALKA]...........................................................................................................1447 FAILURE CODE [D8ALKB]...........................................................................................................1449 FAILURE CODE [D8AQKR]...........................................................................................................1451 FAILURE CODE [DA20MC]...........................................................................................................1453 FAILURE CODE [DA22KK]...........................................................................................................1454 FAILURE CODE [DA25KP]...........................................................................................................1457 FAILURE CODE [DA29KQ]...........................................................................................................1460 FAILURE CODE [DA2LKA]...........................................................................................................1462 FAILURE CODE [DA2LKB]...........................................................................................................1464 FAILURE CODE [DA2QKR]...........................................................................................................1466 FAILURE CODE [DA2RKR]...........................................................................................................1469 FAILURE CODE [DAF0MB]...........................................................................................................1470 FAILURE CODE [DAF0MC]...........................................................................................................1471 FAILURE CODE [DAF8KB]...........................................................................................................1472 FAILURE CODE [DAF9KQ]...........................................................................................................1474 FAILURE CODE [DAFGMC]...........................................................................................................1475 FAILURE CODE [DAFLKA]...........................................................................................................1476 FAILURE CODE [DAFLKB]...........................................................................................................1478 FAILURE CODE [DAFQKR]...........................................................................................................1480 FAILURE CODE [DAZ9KQ]...........................................................................................................1481 FAILURE CODE [DAZQKR]...........................................................................................................1482 FAILURE CODE [DB2QKR]...........................................................................................................1487 FAILURE CODE [DB2RKR]...........................................................................................................1492 FAILURE CODE [DDNRKA]...........................................................................................................1497 FAILURE CODE [DDNRKY]...........................................................................................................1499 FAILURE CODE [DDNS00]...........................................................................................................1501 FAILURE CODE [DGH2KA]...........................................................................................................1503 FAILURE CODE [DGH2KB]...........................................................................................................1505 FAILURE CODE [DHA4KA]...........................................................................................................1507 FAILURE CODE [DHAAMA]...........................................................................................................1509 FAILURE CODE [DHACMA]...........................................................................................................1511 FAILURE CODE [DHPAMA]...........................................................................................................1513 FAILURE CODE [DHPBMA]...........................................................................................................1516 FAILURE CODE [DHS3MA]...........................................................................................................1519 FAILURE CODE [DHS4MA]...........................................................................................................1522 FAILURE CODE [DHS8MA]...........................................................................................................1525 FAILURE CODE [DHS9MA]...........................................................................................................1528 FAILURE CODE [DHSAMA]...........................................................................................................1531 FAILURE CODE [DHSBMA]...........................................................................................................1534 FAILURE CODE [DHSCMA]...........................................................................................................1537 FAILURE CODE [DHSDMA]...........................................................................................................1540 FAILURE CODE [DHSFMA]...........................................................................................................1543 FAILURE CODE [DHSGMA]...........................................................................................................1546 FAILURE CODE [DHSHMA]...........................................................................................................1549 FAILURE CODE [DHSJMA]...........................................................................................................1552 FAILURE CODE [DKR0MA]...........................................................................................................1555 FAILURE CODE [DKR1MA]...........................................................................................................1558 FAILURE CODE [DKULKA]...........................................................................................................1561 FAILURE CODE [DKULKB]...........................................................................................................1563 FAILURE CODE [DKULKY]...........................................................................................................1565 FAILURE CODE [DLM5KA]...........................................................................................................1567 FAILURE CODE [DLM5MB]...........................................................................................................1569 FAILURE CODE [DR21KX]...........................................................................................................1571 FAILURE CODE [DR31KX]...........................................................................................................1573 FAILURE CODE [DV20KB]...........................................................................................................1575 FAILURE CODE [DW43KA]...........................................................................................................1577 FAILURE CODE [DW43KB]...........................................................................................................1579 FAILURE CODE [DW43KY]...........................................................................................................1581 FAILURE CODE [DW45KA]...........................................................................................................1583 FAILURE CODE [DW45KB]...........................................................................................................1586 FAILURE CODE [DW45KY]...........................................................................................................1589 FAILURE CODE [DW4CKY]...........................................................................................................1591 FAILURE CODE [DW91KA]...........................................................................................................1593 FAILURE CODE [DW91KB]...........................................................................................................1595 FAILURE CODE [DW91KY]...........................................................................................................1597 FAILURE CODE [DWA2KA]...........................................................................................................1599 FAILURE CODE [DWA2KB]...........................................................................................................1601 FAILURE CODE [DWA2KY]...........................................................................................................1603 FAILURE CODE [DWK0KA]...........................................................................................................1605 FAILURE CODE [DWK0KB]...........................................................................................................1607 FAILURE CODE [DWK0KY]...........................................................................................................1609 FAILURE CODE [DWK2KA]...........................................................................................................1611 FAILURE CODE [DWK2KB]...........................................................................................................1613 FAILURE CODE [DWK2KY]...........................................................................................................1615 FAILURE CODE [DWK8KA]...........................................................................................................1617 FAILURE CODE [DWK8KB]...........................................................................................................1619 FAILURE CODE [DWK8KY]...........................................................................................................1621 FAILURE CODE [DWN5KA]...........................................................................................................1623 FAILURE CODE [DWN5KB]...........................................................................................................1625 FAILURE CODE [DWN5KY]...........................................................................................................1627 FAILURE CODE [DXA8KA]...........................................................................................................1629 FAILURE CODE [DXA8KB]...........................................................................................................1631 FAILURE CODE [DXA9KA]...........................................................................................................1633 FAILURE CODE [DXA9KB]...........................................................................................................1635 FAILURE CODE [DXE0KA]...........................................................................................................1637 FAILURE CODE [DXE0KB]...........................................................................................................1638 FAILURE CODE [DXE4KA]...........................................................................................................1640 FAILURE CODE [DXE4KB]...........................................................................................................1642 FAILURE CODE [DXE4KY]...........................................................................................................1644 FAILURE CODE [DXE5KA]...........................................................................................................1646 FAILURE CODE [DXE5KB]...........................................................................................................1648 FAILURE CODE [DXE6KA]...........................................................................................................1650 FAILURE CODE [DXE6KB]...........................................................................................................1652 FAILURE CODE [DXE7KA]...........................................................................................................1654 FAILURE CODE [DXE7KB]...........................................................................................................1656 FAILURE CODE [DXE7KY]...........................................................................................................1658 FAILURE CODE [DXE8KA]...........................................................................................................1660 FAILURE CODE [DXE8KB]...........................................................................................................1662 FAILURE CODE [DXE8KY]...........................................................................................................1664 FAILURE CODE [DXE9KA]...........................................................................................................1666 FAILURE CODE [DXE9KB]...........................................................................................................1668 FAILURE CODE [DXE9KY]...........................................................................................................1670 FAILURE CODE [DXEAKA]...........................................................................................................1672 FAILURE CODE [DXEAKB]...........................................................................................................1674 FAILURE CODE [DXEAKY]...........................................................................................................1676 FAILURE CODE [DY20KA]...........................................................................................................1678 FAILURE CODE [DY20MA]...........................................................................................................1680 FAILURE CODE [DY2CKB]...........................................................................................................1682 FAILURE CODE [DY2DKB]...........................................................................................................1685 FAILURE CODE [DY2EKB]...........................................................................................................1687 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1689 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................1689 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................1695 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................1698 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................1700 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................1702 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........1705 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....1706 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................1707 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................1708 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................1709 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1710 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1711 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................................1712 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................1713 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................1714 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................1715 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................1716 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................1718 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................1719 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................1720 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................1721 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................1723 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................1724 E-24 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................1725 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................1726 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................1727 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................1728 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................1729 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................1730 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................1731 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................1732 E-32 ALARM BUZZER CANNOT BE CANCELED............................................................................................1734 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................1735 E-34 SERVICE MODE CANNOT BE SELECTED............................................................................................1736 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................1737 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................1740 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................1742 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................1745 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................1747 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................1750 E-41 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................1751 E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................1753 E-43 HORN DOES NOT SOUND........................................................................................................1754 E-44 HORN DOES NOT STOP SOUNDING................................................................................................1757 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................1759 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................1760 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................1762 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1763 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1764 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1765 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1766 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1767 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1768 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................1769 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1770 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1771 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.............................................................................1773 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................1774 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1775 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).........................................................................1775 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS................................................................................1776 FAILURE MODE AND CAUSE TABLE....................................................................................................1778 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK............................................................................1790 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...................................................................1791 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR................................................................................1794 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................1795 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................1796 H-6 SPEED OR POWER OF BOOM IS LOW...............................................................................................1798 H-7 ARM SPEED OR POWER IS LOW...................................................................................................1802 H-8 BUCKET SPEED OR POWER IS LOW................................................................................................1807 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION............................................................................1810 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................1811 H-11 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................1813 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................1815 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................................1816 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................1817 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................1818 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................................1819 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................1820 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................................1821 H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY......................................................1822 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW....................................................1823 H-21 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................1824 H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................................1826 H-23 TRAVEL SPEED IS LOW........................................................................................................1829 H-24 ONE OF TRACKS DOES NOT RUN.................................................................................................1831 H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................................1832 H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................................1833 H-27 SWINGS ONLY IN ONE DIRECTION...............................................................................................1834 H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................................1835 H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................................1836 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................................1837 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......................1838 H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................................1839 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................................1840 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................1841 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................1842 H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY).....................................................................1843 H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN.....................................................................................1844 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................1845 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................1845 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................1846 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................1847 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................1848 S-4 ENGINE STARTABILITY IS POOR.................................................................................................1850 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................1852 S-6 ENGINE STOPS DURING OPERATION...............................................................................................1854 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................1856 S-8 ENGINE LACKS POWER..........................................................................................................1857 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................1859 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................1861 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................1862 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................1863 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................1864 S-14 OIL PRESSURE DROPS.........................................................................................................1865 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................1867 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................1868 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................1869 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................1870 S-19 VIBRATION IS EXCESSIVE.....................................................................................................1871 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................1872 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................1873 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................1875 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................1876 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................1877 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................1879 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................1880 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1881 CONTENTS............................................................................................................................1882 ABBREVIATION LIST...................................................................................................................1887 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................1892 HOW TO READ THIS MANUAL.........................................................................................................1892 COATING MATERIALS LIST..........................................................................................................1894 SPECIAL TOOLS LIST..............................................................................................................1899 SKETCHES OF SPECIAL TOOLS.......................................................................................................1911 ENGINE AND COOLING SYSTEM...........................................................................................................1917 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................1917 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................1917 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................1920 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................1923 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................1923 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................1928 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................1936 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................1937 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................1946 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................1962 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................1962 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................1963 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................1965 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................1965 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................1969 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................1974 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................1974 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................1975 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................1978 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................1978 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................1980 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................1982 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................1982 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................1984 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................1987 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................1987 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................1990 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................1993 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................1993 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................1995 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY..........................................................................................1997 METHOD FOR REMOVING FAN CLUTCH ASSEMBLY.....................................................................................1997 METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY...................................................................................2001 REMOVE AND INSTALL FAN..........................................................................................................2005 METHOD FOR INSTALLING FAN...................................................................................................2005 METHOD FOR REMOVING FAN.....................................................................................................2005 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................2006 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...........................................................................2006 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY.........................................................................2015 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2027 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2027 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2030 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2034 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2034 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2035 REMOVE AND INSTALL FUEL COOLER ASSEMBLY.........................................................................................2038 METHOD FOR REMOVING FUEL COOLER ASSEMBLY....................................................................................2038 METHOD FOR INSTALLING FUEL COOLER ASSEMBLY..................................................................................2038 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2040 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2040 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2042 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2047 METHOD FOR REMOVING FUEL TANK ASSEMBLY......................................................................................2047 METHOD FOR INSTALLING FUEL TANK ASSEMBLY....................................................................................2051 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2055 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2055 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2061 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2067 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2067 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2073 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2079 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2079 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2079 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2081 METHOD FOR REMOVING AdBlue/DEF STRAINER.....................................................................................2081 METHOD FOR INSTALLING AdBlue/DEF STRAINER...................................................................................2081 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2082 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2082 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2084 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2086 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2087 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2090 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2095 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2095 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2097 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2099 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2099 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2105 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...................................................................................2111 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET..............................................................................2111 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET............................................................................2119 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2127 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2127 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2129 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2134 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2134 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2140 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2146 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2146 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2149 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2152 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2152 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2155 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2158 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2158 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2165 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2171 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2171 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2172 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2174 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2174 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2176 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2179 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2179 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2180 POWER TRAIN.........................................................................................................................2181 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2181 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2181 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2182 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2184 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2184 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2188 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................2197 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................2197 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................2199 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2203 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2203 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2207 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2214 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2214 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2214 UNDERCARRIAGE AND FRAME.............................................................................................................2216 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2216 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2216 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2218 REMOVE AND INSTALL SPROCKET.....................................................................................................2221 METHOD FOR REMOVING SPROCKET................................................................................................2221 METHOD FOR INSTALLING SPROCKET..............................................................................................2221 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2223 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2223 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2224 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2225 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2225 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2226 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2230 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2230 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2231 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2233 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2234 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2235 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2237 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2237 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2238 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2241 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2241 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2243 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2246 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2246 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................................................................................2249 HYDRAULIC SYSTEM....................................................................................................................2253 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2253 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2253 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2255 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2258 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2258 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2259 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2261 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2261 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2263 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2266 METHOD FOR REMOVING MAIN PUMP ASSEMBLY......................................................................................2266 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY....................................................................................2269 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2272 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2272 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2279 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2287 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING..................................................................2287 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY................................................................................2288 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2292 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2292 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2292 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2294 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2294 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2295 WORK EQUIPMENT......................................................................................................................2297 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2297 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2297 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2301 REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM............................................................................2306 METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM.......................................................................2306 METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM.....................................................................2308 REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM.............................................................................2309 METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM........................................................................2309 METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM......................................................................2311 DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY...............................................................................2312 METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY...........................................................................2312 METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY..............................................................................2312 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2313 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2313 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2316 CAB AND ITS ATTACHMENTS.............................................................................................................2322 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2322 METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...................................................................................2322 METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY.................................................................................2328 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2335 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)......................................................................2337 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)....................................................................2337 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2347 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2347 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2350 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2356 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2356 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2363 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2370 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2370 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2375 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2381 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2381 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2383 REMOVE AND INSTALL SEAT BELT....................................................................................................2386 METHOD FOR REMOVING SEAT BELT...............................................................................................2386 METHOD FOR INSTALLING SEAT BELT.............................................................................................2387 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2388 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2388 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2393 ELECTRICAL SYSTEM...................................................................................................................2401 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2401 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2401 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2402 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2404 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2404 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2408 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2413 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2413 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2416 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2420 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR.................................................................................2420 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...............................................................................2421 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2422 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2422 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2422 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2424 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2424 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR........................................................................2425 REMOVE AND INSTALL SCR TEMPERATURE SENSOR.......................................................................................2426 METHOD FOR REMOVING SCR TEMPERATURE SENSOR..................................................................................2426 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................................................................................2428 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................2430 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...............................................................................2430 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY.............................................................................2433 60 MAINTENANCE STANDARD.................................................................................................................2437 CONTENTS............................................................................................................................2438 ABBREVIATION LIST...................................................................................................................2439 ENGINE AND COOLING SYSTEM...........................................................................................................2444 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2444 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2445 POWER TRAIN.........................................................................................................................2447 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2447 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2448 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2450 MAINTENANCE STANDARD OF SPROCKET................................................................................................2452 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................2453 UNDERCARRIAGE AND FRAME.............................................................................................................2455 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2455 MAINTENANCE STANDARD OF IDLER...................................................................................................2457 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2459 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2460 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2461 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2464 MAINTENANCE STANDARD OF SWAMP SHOE..............................................................................................2465 MAINTENANCE STANDARD OF ROAD LINER..............................................................................................2466 HYDRAULIC SYSTEM....................................................................................................................2467 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2467 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2468 MAINTENANCE STANDARD OF LS-EPC VALVE............................................................................................2469 MAINTENANCE STANDARD OF PC-EPC VALVE............................................................................................2470 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2471 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2474 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2477 MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM................................................................................2487 MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM.................................................................................2489 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2491 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2494 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2497 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE..........................................................2499 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................2500 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2502 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...................................................2503 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)....................................................2504 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2505 WORK EQUIPMENT......................................................................................................................2506 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2506 DIMENSION OF ARM............................................................................................................2511 DIMENSIONS OF BUCKET........................................................................................................2513 MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)...................................................................2515 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2516 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2517 80 APPENDIX.............................................................................................................................2519 CONTENTS............................................................................................................................2520 ABBREVIATION LIST...................................................................................................................2522 AIR CONDITIONER SYSTEM..............................................................................................................2527 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2527 AIR CONDITIONER COMPONENT.......................................................................................................2528 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................2530 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................2531 OUTLINE OF REFRIGERATION CYCLE..................................................................................................2532 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2534 AIR CONDITIONER UNIT............................................................................................................2534 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................2534 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2536 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................2538 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2539 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................2539 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................2539 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................2539 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................2540 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................2540 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................2540 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................2541 AIR CONDITIONER CONTROLLER......................................................................................................2542 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2542 COMPRESSOR......................................................................................................................2543 STRUCTURE OF COMPRESSOR.....................................................................................................2543 SPECIFICATIONS OF COMPRESSOR................................................................................................2543 FUNCTION OF COMPRESSOR......................................................................................................2543 CONDENSER.......................................................................................................................2544 STRUCTURE OF CONDENSER......................................................................................................2544 SPECIFICATIONS OF CONDENSER.................................................................................................2544 FUNCTION OF CONDENSER.......................................................................................................2544 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................2546 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2546 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2546 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................2546 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................2546 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................2548 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................2550 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................2552 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................2553 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2554 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2555 TESTING AIR LEAKAGE (DUCT)..........................................................................................................2559 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................2559 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................2561 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................2562 TEST VENT (MODE) CHANGEOVER.........................................................................................................2563 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................2563 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................2565 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................2565 TEST SUNLIGHT SENSOR................................................................................................................2566 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................2566 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................2567 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................2567 TEST RELAYS.........................................................................................................................2568 METHOD FOR TESTING RELAYS.......................................................................................................2568 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................2569 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................2570 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2573 FAILURE CODE [879AKA]...............................................................................................................2575 FAILURE CODE [879AKB]...............................................................................................................2576 FAILURE CODE [879BKA]...............................................................................................................2577 FAILURE CODE [879BKB]...............................................................................................................2579 FAILURE CODE [879CKA]...............................................................................................................2581 FAILURE CODE [879CKB]...............................................................................................................2582 FAILURE CODE [879DKZ]...............................................................................................................2583 FAILURE CODE [879EMC]...............................................................................................................2585 FAILURE CODE [879FMC]...............................................................................................................2586 FAILURE CODE [879GKX]...............................................................................................................2587 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................2589 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................2591 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................2594 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................2596 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................2598 CONNECTION OF SERVICE TOOL..........................................................................................................2601 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................2601 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................2603 HANDLE COMPRESSOR OIL...............................................................................................................2605 METHOD FOR REPLACING DESICCANT......................................................................................................2607 90 CIRCUIT DIAGRAMS.....................................................................................................................2609 CONTENTS............................................................................................................................2610 ABBREVIATION LIST...................................................................................................................2611 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2616 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2616 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................2621 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2622 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................2622 ELECTRICAL CIRCUIT DIAGRAM (1/7)................................................................................................2626 ELECTRICAL CIRCUIT DIAGRAM (2/7)................................................................................................2627 ELECTRICAL CIRCUIT DIAGRAM (3/7)................................................................................................2628 ELECTRICAL CIRCUIT DIAGRAM (4/7)................................................................................................2629 ELECTRICAL CIRCUIT DIAGRAM (5/7)................................................................................................2630 ELECTRICAL CIRCUIT DIAGRAM (6/7)................................................................................................2631 ELECTRICAL CIRCUIT DIAGRAM (7/7)................................................................................................2632 INDEX...................................................................................................................................2633
DESCRIPTION:
KOMATSU PC210LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06516-C1 – 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 30/12/24
