Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00101 PDF

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Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00101 –  PDF DOWNLOAD

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Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00101 –  PDF DOWNLOAD

Language : English
Pages : 2850
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00101 –  PDF DOWNLOAD

• SERIAL NUMBERS 5002 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 56
PRACTICAL USE OF KOMTRAX 57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
HOW TO READ ELECTRICAL WIRE CODE 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 77
STANDARD TIGHTENING TORQUE TABLE 80
CONVERSION TABLE 87
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC228USLC-11 . 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC228USLC-11 . 103
SPECIFICATIONS 104
SPECIFICATIONS: PC228USLC-11 104
WEIGHT TABLE 107
WEIGHT TABLE: PC228USLC-11 107
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 109
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE . 109
10 STRUCTURE AND FUNCTION . 111
CONTENTS 112
ABBREVIATION LIST . 115
UREA SCR SYSTEM . 121
LAYOUT DRAWING OF UREA SCR SYSTEM . 121
UREA SCR SYSTEM DIAGRAM . 126
FUNCTION OF UREA SCR SYSTEM . 127
FUNCTION OF AdBlue/DEF SYSTEM . 127
INDUCEMENT STRATEGY . 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK . 140
AdBlue/DEF PUMP . 142
AdBlue/DEF INJECTOR . 143
AdBlue/DEF HOSE . 144
AdBlue/DEF TANK HEATING VALVE . 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 150
LAYOUT DRAWING OF ENGINE SYSTEM . 150
SPECIFICATIONS OF ENGINE SYSTEM . 151
FUNCTION OF ENGINE SYSTEM . 151
ENGINE CONTROL SYSTEM . 152
ENGINE CONTROL SYSTEM DIAGRAM . 152
FUNCTION OF ENGINE CONTROL SYSTEM . 153
AUTO-DECELERATION SYSTEM 155
AUTO-DECELERATION SYSTEM DIAGRAM 155
FUNCTION OF AUTO-DECELERATION SYSTEM 155
OPERATION OF AUTO-DECELERATION SYSTEM . 156
ENGINE AUTOMATIC WARM-UP SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 158
OVERHEAT PREVENTION SYSTEM 159
OVERHEAT PREVENTION SYSTEM DIAGRAM 159
FUNCTION OF OVERHEAT PREVENTION SYSTEM 160
TURBOCHARGER PROTECTION SYSTEM 162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 163
AUTOMATIC IDLE STOP SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 164
COMPONENT PARTS OF ENGINE SYSTEM 167
VGT . 167
EGR SYSTEM 170
EGR VALVE . 172
EGR COOLER 174
KCCV SYSTEM . 175
KCCV VENTILATOR . 177
KDPF 179
COOLING SYSTEM 184
LAYOUT DRAWING OF COOLING SYSTEM 184
SPECIFICATIONS OF COOLING SYSTEM 185
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 186
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 186
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 187
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 188
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 188
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 188
COMPONENT PARTS OF COOLING SYSTEM . 190
FAN CLUTCH 190
CONTROL SYSTEM 191
LAYOUT DRAWING OF CONTROL SYSTEM 191
MACHINE MONITOR SYSTEM 194
MACHINE MONITOR SYSTEM DIAGRAM 194
FUNCTION OF MACHINE MONITOR SYSTEM 194
KomVision SYSTEM 196
LAYOUT DRAWING OF KomVision SYSTEM 196
KomVision SYSTEM DIAGRAM 198
FUNCTION OF KomVision SYSTEM 198
KOMTRAX SYSTEM 200
KOMTRAX SYSTEM DIAGRAM 200
FUNCTION OF KOMTRAX SYSTEM 200
COMPONENT PARTS OF CONTROL SYSTEM . 201
MACHINE MONITOR . 201
KomVision CONTROLLER 215
KomVision CAMERA 219
KOMTRAX TERMINAL 219
PUMP CONTROLLER . 221
RESISTOR FOR PC-EPC VALVE . 225
CAN TERMINATING RESISTOR 226
ENGINE CONTROLLER . 227
FUEL CONTROL DIAL . 233
HYDRAULIC SYSTEM 235
LAYOUT DRAWING OF HYDRAULIC SYSTEM 235
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 . 255
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 258
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 258
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 259
PUMP AND VALVE CONTROL SYSTEM . 264
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 264
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 265
COMPONENT PARTS OF HYDRAULIC SYSTEM . 267
HYDRAULIC TANK 267
MAIN PUMP . 269
CONTROL VALVE . 294
WORK EQUIPMENT SYSTEM . 352
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 352
ONE-TOUCH POWER MAXIMIZING SYSTEM . 357
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 357
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 358
PPC LOCK SYSTEM . 359
PPC LOCK SYSTEM DIAGRAM . 359
FUNCTION OF PPC LOCK SYSTEM . 359
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 360
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 360
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 360
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 361
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 363
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 363
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 364
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 365
WORK EQUIPMENT AND SWING PPC VALVE 365
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 370
2ND-LINE ATTACHMENT PPC VALVE . 375
SOLENOID VALVE 377
ANTI-DROP VALVE FOR BOOM 381
ANTI-DROP VALVE FOR ARM . 385
BOOM ANGLE POTENTIOMETER 389
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 390
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 392
PILOT CIRCUIT ACCUMULATOR . 394
ATTACHMENT CIRCUIT ACCUMULATOR 395
SWING SYSTEM 396
LAYOUT DRAWING OF SWING SYSTEM 396
SWING CONTROL SYSTEM DIAGRAM 400
FUNCTION OF SWING CONTROL SYSTEM 400
COMPONENT PARTS OF SWING SYSTEM . 404
SWING MOTOR . 404
SWING MACHINERY . 415
SWING CIRCLE 416
TRAVEL SYSTEM . 418
LAYOUT DRAWING OF TRAVEL SYSTEM . 418
TRAVEL CONTROL SYSTEM DIAGRAM . 422
FUNCTION OF TRAVEL CONTROL SYSTEM . 422
COMPONENT PARTS OF TRAVEL SYSTEM 424
TRAVEL MOTOR 424
FINAL DRIVE . 437
TRAVEL PPC VALVE 438
CENTER SWIVEL JOINT . 443
UNDERCARRIAGE AND FRAME . 445
LAYOUT DRAWING OF UNDERCARRIAGE . 445
SPECIFICATIONS OF UNDERCARRIAGE . 446
WORK EQUIPMENT 447
STRUCTURE OF WORK EQUIPMENT . 447
FUNCTION OF WORK EQUIPMENT 448
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 449
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 449
BUCKET CLEARANCE ADJUSTMENT SHIM 450
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 450
CAB AND ITS ATTACHMENTS . 451
ROPS CAB 451
STRUCTURE OF ROPS CAB . 451
FUNCTION OF ROPS CAB 451
CAB MOUNT . 452
STRUCTURE OF CAB MOUNT 452
FUNCTION OF CAB MOUNT . 452
CAB TIPPING STOPPER . 453
STRUCTURE OF CAB TIPPING STOPPER 453
FUNCTION OF CAB TIPPING STOPPER . 453
TAKE WIRING HARNESS OUT OF CAB 454
20 STANDARD VALUE TABLE . 455
CONTENTS 456
ABBREVIATION LIST . 457
STANDARD VALUE TABLE FOR ENGINE . 463
STANDARD VALUE TABLE FOR ENGINE: PC228USLC-11 . 463
STANDARD VALUE TABLE FOR MACHINE 468
STANDARD VALUE TABLE FOR MACHINE: PC228USLC-11 468
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 482
30 TESTING AND ADJUSTING 487
CONTENTS 488
ABBREVIATION LIST . 491
RELATED INFORMATION ON TESTING AND ADJUSTING 497
TOOLS FOR TESTING AND ADJUSTING . 497
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 503
ENGINE AND COOLING SYSTEM . 504
TEST ENGINE SPEED . 504
METHOD FOR TESTING ENGINE SPEED . 504
TEST BOOST PRESSURE . 507
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 507
METHOD FOR TESTING BOOST PRESSURE . 508
TEST EXHAUST GAS COLOR 510
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 510
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 511
TEST AND ADJUST VALVE CLEARANCE . 513
METHOD FOR TESTING VALVE CLEARANCE 513
METHOD FOR ADJUSTING VALVE CLEARANCE 514
TEST COMPRESSION PRESSURE . 515
METHOD FOR TESTING COMPRESSION PRESSURE . 515
TEST BLOWBY PRESSURE 520
METHOD FOR TESTING BLOWBY PRESSURE 520
TEST ENGINE OIL PRESSURE 522
METHOD FOR TESTING ENGINE OIL PRESSURE 522
TEST EGR VALVE AND VGT OIL PRESSURE . 523
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 523
TEST FUEL PRESSURE 525
METHOD FOR TESTING FUEL PRESSURE 526
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 531
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 532
BLEEDING AIR FROM FUEL SYSTEM . 538
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 538
TEST FUEL CIRCUIT FOR LEAKAGE . 539
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 539
HANDLE CYLINDER CUT-OUT MODE OPERATION 541
HANDLE NO-INJECTION CRANKING OPERATION 542
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 543
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 543
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 543
TEST COOLING FAN SPEED 545
METHOD FOR TESTING COOLING FAN SPEED 545
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 546
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 546
TEST SCR RELATED FUNCTIONS 547
TEST AdBlue/DEF PUMP RAISED PRESSURE 550
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 553
TEST AdBlue/DEF LINE HEATER RELAY 1 . 557
TEST AdBlue/DEF LINE HEATER RELAY 2 . 560
TEST AdBlue/DEF PUMP HEATER RELAY . 562
TEST AdBlue/DEF TANK HEATER VALVE . 566
TEST DENITRATION EFFICIENCY OF SCR 568
CLEAN AdBlue/DEF TANK . 573
METHOD FOR CLEANING AdBlue/DEF TANK . 573
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 577
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 577
POWER TRAIN . 579
TEST SWING CIRCLE BEARING CLEARANCE . 579
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 579
UNDERCARRIAGE AND FRAME . 580
TEST AND ADJUST TRACK TENSION . 580
METHOD FOR TESTING TRACK TENSION 580
METHOD FOR ADJUSTING TRACK TENSION 580
HYDRAULIC SYSTEM 582
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 582
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 582
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 582
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 586
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 587
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 588
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 589
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 597
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
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 601
METHOD FOR TESTING 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 . 605
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 605
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 607
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 618
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 618
TEST PUMP SWASH PLATE SENSOR 619
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 619
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 620
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 620
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 621
METHOD FOR TESTING OF THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM LOCK VALVE 621
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 621
TEST OIL LEAKAGE 623
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 623
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 623
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 624
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 624
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 625
BLEED AIR FROM HYDRAULIC CIRCUIT 626
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 628
WORK EQUIPMENT 630
ADJUST BOOM ANGLE POTENTIOMETER . 630
METHOD FOR ADJUSTING BOOM ANGLE POTENTIOMETER . 630
CAB AND ITS ATTACHMENTS . 631
TEST CAB TIPPING STOPPER 631
METHOD FOR TESTING CAB TIPPING STOPPER 631
METHOD FOR ADJUSTING MIRRORS 632
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 632
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 633
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 634
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 635
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (C) 636
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (C) 636
PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (D) . 638
ELECTRICAL SYSTEM . 639
SET AND OPERATE MACHINE MONITOR . 639
OPERATOR MODE . 642
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 643
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 643
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 644
CHECKING FUNCTION OF SERVICE METER 644
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 644
SERVICE MODE 647
METHOD FOR OPERATING SERVICE MODE . 647
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 649
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 656
ABNORMALITY RECORD MENU . 667
METHOD FOR CONFIRMING MAINTENANCE RECORD 672
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 673
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 677
DEFAULT MENU 678
DIAGNOSTIC TESTS MENU . 686
ADJUSTMENT MENU . 695
METHOD FOR PERFORMING NO-INJECTION CRANKING . 716
KOMTRAX SETTINGS MENU . 717
METHOD FOR DISPLAYING SERVICE MESSAGE . 720
METHOD FOR STARTING UP KOMTRAX TERMINAL . 722
ADJUST REARVIEW CAMERA ANGLE 727
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 727
ADJUST KomVision CAMERA ANGLE . 729
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 730
ADJUST KomVision RELATED ITEMS 732
SETTING OF KomVision (MAIN SETTING) . 732
SETTING OF KomVision (CAMERA SETTING) . 734
SETTING OF KomVision (CAMERA CALIBRATION) . 736
KomVision screen – Check 12 m visibility 749
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 752
HANDLE BATTERY DISCONNECT SWITCH 753
TEST DIODES . 754
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 754
METHOD FOR TESTING DIODE USING ANALOG TESTER 754
Pm CLINIC . 755
Pm CLINIC SERVICE . 755
Pm CLINIC CHECK SHEET: PC228USLC-11 . 756
40 TROUBLESHOOTING 767
CONTENTS 768
ABBREVIATION LIST . 779
RELATED INFORMATION ON TROUBLESHOOTING 785
GENERAL TROUBLESHOOTING POINTS 785
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 787
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 799
CHECKS BEFORE TROUBLESHOOTING . 801
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 803
WALK-AROUND CHECK . 803
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 805
CHECK FUEL LEVEL AND TYPE . 805
CHECK IMPURE INGREDIENT IN FUEL . 805
CHECK FUEL PREFILTER 806
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 806
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 807
CHECK MAIN FILTER . 808
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 810
CHECK COOLANT LEVEL (RESERVOIR TANK) 811
CHECK CLOGGING OF AIR CLEANER . 811
OUTER ELEMENT – CLEAN . 812
ELEMENTS – REPLACE 814
CHECK HYDRAULIC OIL LEVEL . 815
CHECK HYDRAULIC OIL STRAINER 816
CHECK HYDRAULIC FILTER 817
CHECK OIL LEVEL IN SWING MACHINERY CASE . 818
CHECK OIL LEVEL IN DAMPER CASE 819
CHECK OIL LEVEL IN FINAL DRIVE CASE . 819
BLEED AIR FROM FUEL SYSTEM 820
BLEED AIR FROM HYDRAULIC SYSTEM . 820
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 820
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 826
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 826
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 826
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 827
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 828
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK . 829
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 833
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 836
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 840
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 842
CONNECTORS LIST AND LAYOUT 845
CONNECTOR CONTACT IDENTIFICATION 859
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 899
FUSE LOCATION TABLE . 905
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 908
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 912
FAILURE CODES TABLE . 914
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 932
FAILURE CODE [879AKA] . 932
FAILURE CODE [879AKB] . 933
FAILURE CODE [879BKA] . 934
FAILURE CODE [879BKB] . 936
FAILURE CODE [879CKA] . 938
FAILURE CODE [879CKB] . 939
FAILURE CODE [879DKZ] . 940
FAILURE CODE [879EMC] . 942
FAILURE CODE [879FMC] . 943
FAILURE CODE [879GKX] . 944
FAILURE CODE [989L00] . 946
FAILURE CODE [989M00] . 947
FAILURE CODE [989N00] . 948
FAILURE CODE [A1U0N3] . 949
FAILURE CODE [A1U0N4] . 951
FAILURE CODE [A900FR] . 953
FAILURE CODE [A900N6] . 954
FAILURE CODE [A900NY] . 955
FAILURE CODE [AA10NX] . 956
FAILURE CODE [AB00KE] . 958
FAILURE CODE [AQ10N3] . 960
FAILURE CODE [AS00N3] . 962
FAILURE CODE [AS00R2] . 964
FAILURE CODE [AS00R3] . 965
FAILURE CODE [AS00R4] . 966
FAILURE CODE [AS00R5] . 967
FAILURE CODE [AS00R6] . 968
FAILURE CODE [AS00ZK] . 969
FAILURE CODE [AS10KM] . 970
FAILURE CODE [AS10NR] . 971
FAILURE CODE [AS10NT] . 972
FAILURE CODE [B@BAZG] . 973
FAILURE CODE [B@BAZK] . 975
FAILURE CODE [B@BCNS] . 977
FAILURE CODE [B@BCQA] . 979
FAILURE CODE [B@BCZK] . 981
FAILURE CODE [B@HANS] . 983
FAILURE CODE [CA115] 985
FAILURE CODE [CA122] 990
FAILURE CODE [CA123] 993
FAILURE CODE [CA131] 995
FAILURE CODE [CA132] 997
FAILURE CODE [CA144] 999
FAILURE CODE [CA145] 1001
FAILURE CODE [CA153] 1003
FAILURE CODE [CA154] 1005
FAILURE CODE [CA187] 1007
FAILURE CODE [CA221] 1009
FAILURE CODE [CA222] 1011
FAILURE CODE [CA227] 1013
FAILURE CODE [CA234] 1014
FAILURE CODE [CA238] 1015
FAILURE CODE [CA239] 1016
FAILURE CODE [CA249] 1017
FAILURE CODE [CA256] 1019
FAILURE CODE [CA271] 1021
FAILURE CODE [CA272] 1023
FAILURE CODE [CA322] 1025
FAILURE CODE [CA323] 1027
FAILURE CODE [CA324] 1029
FAILURE CODE [CA325] 1031
FAILURE CODE [CA331] 1033
FAILURE CODE [CA332] 1035
FAILURE CODE [CA343] 1037
FAILURE CODE [CA351] 1039
FAILURE CODE [CA352] 1041
FAILURE CODE [CA356] 1043
FAILURE CODE [CA357] 1045
FAILURE CODE [CA386] 1047
FAILURE CODE [CA428] 1049
FAILURE CODE [CA429] 1051
FAILURE CODE [CA435] 1053
FAILURE CODE [CA441] 1055
FAILURE CODE [CA442] 1057
FAILURE CODE [CA449] 1058
FAILURE CODE [CA451] 1059
FAILURE CODE [CA452] 1061
FAILURE CODE [CA488] 1063
FAILURE CODE [CA515] 1066
FAILURE CODE [CA516] 1068
FAILURE CODE [CA553] 1070
FAILURE CODE [CA555] 1071
FAILURE CODE [CA556] 1073
FAILURE CODE [CA559] 1075
FAILURE CODE [CA595] 1078
FAILURE CODE [CA687] 1080
FAILURE CODE [CA689] 1082
FAILURE CODE [CA691] 1085
FAILURE CODE [CA692] 1087
FAILURE CODE [CA697] 1089
FAILURE CODE [CA698] 1090
FAILURE CODE [CA731] 1091
FAILURE CODE [CA778] 1093
FAILURE CODE [CA1117] .1098
FAILURE CODE [CA1664] .1099
FAILURE CODE [CA1669] .1102
FAILURE CODE [CA1673] .1103
FAILURE CODE [CA1677] .1104
FAILURE CODE [CA1678] .1105
FAILURE CODE [CA1682] .1106
FAILURE CODE [CA1683] .1110
FAILURE CODE [CA1684] .1112
FAILURE CODE [CA1686] .1114
FAILURE CODE [CA1691] .1115
FAILURE CODE [CA1694] .1118
FAILURE CODE [CA1695] .1121
FAILURE CODE [CA1696] .1123
FAILURE CODE [CA1712] .1125
FAILURE CODE [CA1713] .1128
FAILURE CODE [CA1714] .1131
FAILURE CODE [CA1715] .1132
FAILURE CODE [CA1776] .1133
FAILURE CODE [CA1777] .1136
FAILURE CODE [CA1843] .1139
FAILURE CODE [CA1844] .1141
FAILURE CODE [CA1879] .1143
FAILURE CODE [CA1881] .1145
FAILURE CODE [CA1883] .1147
FAILURE CODE [CA1885] .1151
FAILURE CODE [CA1887] .1153
FAILURE CODE [CA1921] .1155
FAILURE CODE [CA1922] .1158
FAILURE CODE [CA1942] .1163
FAILURE CODE [CA1993] .1165
FAILURE CODE [CA2185] .1167
FAILURE CODE [CA2186] .1168
FAILURE CODE [CA2249] .1170
FAILURE CODE [CA2271] .1173
FAILURE CODE [CA2272] .1175
FAILURE CODE [CA2288] .1177
FAILURE CODE [CA2311] .1179
FAILURE CODE [CA2349] .1181
FAILURE CODE [CA2353] .1183
FAILURE CODE [CA2357] .1185
FAILURE CODE [CA2381] .1188
FAILURE CODE [CA2382] .1190
FAILURE CODE [CA2383] .1193
FAILURE CODE [CA2386] .1195
FAILURE CODE [CA2387] .1197
FAILURE CODE [CA2555] .1200
FAILURE CODE [CA2556] .1202
FAILURE CODE [CA2637] .1204
FAILURE CODE [CA2639] .1206
FAILURE CODE [CA2771] .1208
FAILURE CODE [CA2777] .1213
FAILURE CODE [CA2976] .1216
FAILURE CODE [CA3133] .1218
FAILURE CODE [CA3134] .1220
FAILURE CODE [CA3135] .1222
FAILURE CODE [CA3142] .1225
FAILURE CODE [CA3143] .1226
FAILURE CODE [CA3144] .1227
FAILURE CODE [CA3146] .1230
FAILURE CODE [CA3147] .1231
FAILURE CODE [CA3148] .1232
FAILURE CODE [CA3151] .1235
FAILURE CODE [CA3165] .1241
FAILURE CODE [CA3229] .1243
FAILURE CODE [CA3231] .1246
FAILURE CODE [CA3232] .1249
FAILURE CODE [CA3235] .1254
FAILURE CODE [CA3239] .1257
FAILURE CODE [CA3241] .1260
FAILURE CODE [CA3242] .1262
FAILURE CODE [CA3251] .1265
FAILURE CODE [CA3253] .1267
FAILURE CODE [CA3254] .1271
FAILURE CODE [CA3255] .1275
FAILURE CODE [CA3256] .1278
FAILURE CODE [CA3311] .1281
FAILURE CODE [CA3312] .1284
FAILURE CODE [CA3313] .1287
FAILURE CODE [CA3314] .1288
FAILURE CODE [CA3315] .1289
FAILURE CODE [CA3316] .1292
FAILURE CODE [CA3317] .1293
FAILURE CODE [CA3318] .1294
FAILURE CODE [CA3319] .1297
FAILURE CODE [CA3321] .1299
FAILURE CODE [CA3322] .1301
FAILURE CODE [CA3419] .1303
FAILURE CODE [CA3421] .1305
FAILURE CODE [CA3497] .1307
FAILURE CODE [CA3498] .1308
FAILURE CODE [CA3543] .1309
FAILURE CODE [CA3545] .1315
FAILURE CODE [CA3547] .1317
FAILURE CODE [CA3558] .1318
FAILURE CODE [CA3559] .1320
FAILURE CODE [CA3562] .1322
FAILURE CODE [CA3563] .1324
FAILURE CODE [CA3567] .1327
FAILURE CODE [CA3568] .1330
FAILURE CODE [CA3571] .1335
FAILURE CODE [CA3572] .1337
FAILURE CODE [CA3574] .1339
FAILURE CODE [CA3575] .1342
FAILURE CODE [CA3577] .1344
FAILURE CODE [CA3578] .1346
FAILURE CODE [CA3582] .1348
FAILURE CODE [CA3583] .1357
FAILURE CODE [CA3596] .1359
FAILURE CODE [CA3649] .1363
FAILURE CODE [CA3681] .1366
FAILURE CODE [CA3682] .1371
FAILURE CODE [CA3713] .1376
FAILURE CODE [CA3717] .1379
FAILURE CODE [CA3718] .1380
FAILURE CODE [CA3725] .1381
FAILURE CODE [CA3741] .1384
FAILURE CODE [CA3748] .1385
FAILURE CODE [CA3751] .1387
FAILURE CODE [CA3755] .1389
FAILURE CODE [CA3866] .1391
FAILURE CODE [CA3867] .1395
FAILURE CODE [CA3868] .1398
FAILURE CODE [CA3899] .1403
FAILURE CODE [CA3911] .1405
FAILURE CODE [CA3912] .1410
FAILURE CODE [CA3932] .1412
FAILURE CODE [CA3933] .1414
FAILURE CODE [CA3934] .1416
FAILURE CODE [CA3935] .1419
FAILURE CODE [CA3936] .1421
FAILURE CODE [CA4151] .1423
FAILURE CODE [CA4152] .1429
FAILURE CODE [CA4155] .1434
FAILURE CODE [CA4156] .1436
FAILURE CODE [CA4157] .1439
FAILURE CODE [CA4158] .1441
FAILURE CODE [CA4159] .1442
FAILURE CODE [CA4161] .1443
FAILURE CODE [CA4162] .1446
FAILURE CODE [CA4163] .1449
FAILURE CODE [CA4164] .1450
FAILURE CODE [CA4165] .1452
FAILURE CODE [CA4166] .1454
FAILURE CODE [CA4168] .1456
FAILURE CODE [CA4169] .1460
FAILURE CODE [CA4171] .1464
FAILURE CODE [CA4249] .1468
FAILURE CODE [CA4251] .1472
FAILURE CODE [CA4259] .1476
FAILURE CODE [CA4261] .1479
FAILURE CODE [CA4277] .1482
FAILURE CODE [CA4281] .1485
FAILURE CODE [CA4459] .1488
FAILURE CODE [CA4461] .1490
FAILURE CODE [CA4658] .1493
FAILURE CODE [CA4731] .1496
FAILURE CODE [CA4732] .1497
FAILURE CODE [CA4739] .1498
FAILURE CODE [CA4768] .1499
FAILURE CODE [CA4769] .1501
FAILURE CODE [CA4842] .1504
FAILURE CODE [CA4952] .1507
FAILURE CODE [CA5115] .1509
FAILURE CODE [CA5179] .1512
FAILURE CODE [CA5181] .1514
FAILURE CODE [CA5383] .1516
FAILURE CODE [D110KB] .1518
FAILURE CODE [D19JKZ] .1520
FAILURE CODE [D811MC] .1523
FAILURE CODE [D862KA] .1524
FAILURE CODE [D8ALKA] .1525
FAILURE CODE [D8ALKB] .1527
FAILURE CODE [D8AQKR] .1529
FAILURE CODE [DA20MC] .1533
FAILURE CODE [DA22KK] .1534
FAILURE CODE [DA25KP] .1537
FAILURE CODE [DA29KQ] .1540
FAILURE CODE [DA2LKA] .1543
FAILURE CODE [DA2LKB] .1545
FAILURE CODE [DA2QKR] .1547
FAILURE CODE [DA2RKR] .1552
FAILURE CODE [DAF0KM] .1557
FAILURE CODE [DAF0MB] .1558
FAILURE CODE [DAF0MC] .1559
FAILURE CODE [DAF8KB] .1560
FAILURE CODE [DAF9KQ] .1562
FAILURE CODE [DAFGMC] .1563
FAILURE CODE [DAFLKA] .1564
FAILURE CODE [DAFLKB] .1566
FAILURE CODE [DAFQKR] .1568
FAILURE CODE [DAZ9KQ] .1572
FAILURE CODE [DAZQKR] .1573
FAILURE CODE [DB2QKR] .1577
FAILURE CODE [DB2RKR] .1582
FAILURE CODE [DBP0KM] .1588
FAILURE CODE [DBP0KT] .1589
FAILURE CODE [DBPQKR] .1590
FAILURE CODE [DDNRKA] .1595
FAILURE CODE [DDNRKY] .1597
FAILURE CODE [DDNS00] .1599
FAILURE CODE [DFB1KZ] .1601
FAILURE CODE [DFB2KZ] .1603
FAILURE CODE [DFB3L8] .1605
FAILURE CODE [DFB4L8] .1607
FAILURE CODE [DFB5KZ] .1609
FAILURE CODE [DFB6KZ] .1611
FAILURE CODE [DGH2KA] .1613
FAILURE CODE [DGH2KB] .1615
FAILURE CODE [DHA4KA] .1617
FAILURE CODE [DHAAMA] .1619
FAILURE CODE [DHACMA] .1621
FAILURE CODE [DHPAMA] .1623
FAILURE CODE [DHPBMA] .1625
FAILURE CODE [DHS3MA] .1627
FAILURE CODE [DHS4MA] .1629
FAILURE CODE [DHS8MA] .1631
FAILURE CODE [DHS9MA] .1633
FAILURE CODE [DHSAMA] .1635
FAILURE CODE [DHSBMA] .1637
FAILURE CODE [DHSCMA] .1639
FAILURE CODE [DHSDMA] .1641
FAILURE CODE [DHSFMA] .1643
FAILURE CODE [DHSGMA] .1645
FAILURE CODE [DHSHMA] .1647
FAILURE CODE [DHSJMA] .1649
FAILURE CODE [DHX1MA] .1651
FAILURE CODE [DKR0MA] .1652
FAILURE CODE [DKR1MA] .1655
FAILURE CODE [DKULKA] .1658
FAILURE CODE [DKULKB] .1660
FAILURE CODE [DKULKY] .1662
FAILURE CODE [DLM5KA] .1664
FAILURE CODE [DLM5MB] .1666
FAILURE CODE [DR10KA] .1669
FAILURE CODE [DR21KX] .1672
FAILURE CODE [DR31KX] .1674
FAILURE CODE [DUMBKA] .1676
FAILURE CODE [DUMBKB] .1678
FAILURE CODE [DV20KB] .1680
FAILURE CODE [DW43KA] .1682
FAILURE CODE [DW43KB] .1684
FAILURE CODE [DW43KY] .1686
FAILURE CODE [DW45KA] .1688
FAILURE CODE [DW45KB] .1691
FAILURE CODE [DW45KY] .1694
FAILURE CODE [DW4CKY] .1696
FAILURE CODE [DW4GKA] .1698
FAILURE CODE [DW91KA] .1700
FAILURE CODE [DW91KB] .1702
FAILURE CODE [DW91KY] .1704
FAILURE CODE [DWA2KA] .1706
FAILURE CODE [DWA2KB] .1708
FAILURE CODE [DWA2KY] .1710
FAILURE CODE [DWK0KA] .1712
FAILURE CODE [DWK0KB] .1714
FAILURE CODE [DWK0KY] .1716
FAILURE CODE [DWK2KA] .1718
FAILURE CODE [DWK2KB] .1720
FAILURE CODE [DWK2KY] .1722
FAILURE CODE [DWK8KA] .1724
FAILURE CODE [DWK8KB] .1726
FAILURE CODE [DWK8KY] .1728
FAILURE CODE [DWN5KY] .1730
FAILURE CODE [DXA8KA] .1732
FAILURE CODE [DXA8KB] .1734
FAILURE CODE [DXA9KA] .1736
FAILURE CODE [DXA9KB] .1738
FAILURE CODE [DXE0KA] .1740
FAILURE CODE [DXE0KB] .1742
FAILURE CODE [DXE4KA] .1744
FAILURE CODE [DXE4KB] .1746
FAILURE CODE [DXE4KY] .1748
FAILURE CODE [DXE5KA] .1750
FAILURE CODE [DXE5KB] .1752
FAILURE CODE [DXE6KA] .1754
FAILURE CODE [DXE6KB] .1756
FAILURE CODE [DXE7KA] .1758
FAILURE CODE [DXE7KB] .1760
FAILURE CODE [DXE7KY] .1762
FAILURE CODE [DXE8KA] .1764
FAILURE CODE [DXE8KB] .1766
FAILURE CODE [DXE8KY] .1768
FAILURE CODE [DXE9KA] .1770
FAILURE CODE [DXE9KB] .1772
FAILURE CODE [DXE9KY] .1774
FAILURE CODE [DXEAKA] .1776
FAILURE CODE [DXEAKB] .1778
FAILURE CODE [DXEAKY] .1780
FAILURE CODE [DY20KA] .1782
FAILURE CODE [DY20MA] .1784
FAILURE CODE [DY2CKB] .1786
FAILURE CODE [DY2DKB] .1788
FAILURE CODE [DY2EKB] .1790
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1792
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1792
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1798
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1801
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1803
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1805
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1808
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1809
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1810
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1811
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1812
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1813
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1814
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1815
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1816
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1817
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1818
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1819
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1821
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1822
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1823
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1824
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1826
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1827
E-24 FUNCTION SWITCH DOES NOT OPERATE .1828
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1829
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1830
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1831
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1832
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1833
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1834
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1835
E-32 ALARM BUZZER CANNOT BE CANCELED 1837
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1838
E-34 SERVICE MODE CANNOT BE SELECTED 1839
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1840
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1843
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1845
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1848
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1850
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1852
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1853
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1855
E-43 HORN DOES NOT SOUND 1856
E-44 HORN DOES NOT STOP SOUNDING 1859
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1861
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1862
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1864
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1865
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1866
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1867
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1868
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1869
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1870
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1871
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1872
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1873
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1875
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1877
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1878
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1878
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1879
FAILURE MODE AND CAUSE TABLE 1881
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1893
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1894
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1896
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1897
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1898
H-6 SPEED OR POWER OF BOOM IS LOW .1900
H-7 ARM SPEED OR POWER IS LOW .1905
H-8 BUCKET SPEED OR POWER IS LOW 1910
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1913
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1914
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1916
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1918
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1919
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1920
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1921
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1922
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1923
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1924
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1925
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1926
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1927
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1929
H-23 TRAVEL SPEED IS LOW 1932
H-24 ONE OF TRACKS DOES NOT RUN .1934
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1935
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1936
H-27 SWINGS ONLY IN ONE DIRECTION .1937
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1938
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1939
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1940
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1941
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1942
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1943
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1944
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1945
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1946
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1947
TROUBLESHOOTING OF ENGINE (S-MODE) 1948
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1948
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1949
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1950
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1951
S-4 ENGINE STARTABILITY IS POOR .1953
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1955
S-6 ENGINE STOPS DURING OPERATION .1957
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1959
S-8 ENGINE LACKS POWER 1960
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1962
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1964
S-11 OIL BECOMES CONTAMINATED QUICKLY .1965
S-12 FUEL CONSUMPTION IS EXCESSIVE 1966
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1967
S-14 OIL PRESSURE DROPS .1968
S-15 FUEL MIXES INTO ENGINE OIL .1970
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1971
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1972
S-18 UNUSUAL NOISE IS HEARD .1974
S-19 VIBRATION IS EXCESSIVE .1975
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1976
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1977
S-22 ACTIVE REGENERATION TAKES TIME .1979
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1980
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1981
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1983
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1984
50 DISASSEMBLY AND ASSEMBLY .1985
CONTENTS 1986
ABBREVIATION LIST .1991
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1997
HOW TO READ THIS MANUAL .1997
COATING MATERIALS LIST 1999
SPECIAL TOOLS LIST 2003
SKETCHES OF SPECIAL TOOLS .2022
ENGINE AND COOLING SYSTEM .2028
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2028
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2028
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2031
REMOVE AND INSTALL INJECTOR ASSEMBLY 2034
METHOD FOR REMOVING INJECTOR ASSEMBLY .2035
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2040
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2050
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2051
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2060
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2076
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2076
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2077
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2079
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2079
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2082
REMOVE AND INSTALL STARTER ASSEMBLY .2086
METHOD FOR REMOVING STARTER ASSEMBLY 2086
METHOD FOR INSTALLING STARTER ASSEMBLY 2088
REMOVE AND INSTALL ALTERNATOR BELT 2091
METHOD FOR REMOVING ALTERNATOR BELT .2091
METHOD FOR INSTALLING ALTERNATOR BELT .2094
REMOVE AND INSTALL RADIATOR ASSEMBLY 2097
METHOD FOR REMOVING RADIATOR ASSEMBLY .2097
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2100
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2104
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2104
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2111
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2118
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2118
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2120
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2122
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2122
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2127
REMOVE AND INSTALL ENGINE ASSEMBLY 2132
METHOD FOR REMOVING ENGINE ASSEMBLY .2132
METHOD FOR INSTALLING ENGINE ASSEMBLY .2142
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2154
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2154
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2159
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2164
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2164
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2165
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2168
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2168
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2170
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2172
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2172
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2173
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2175
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2175
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2181
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2188
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2189
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2196
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2202
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2203
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2210
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2215
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2215
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2216
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2218
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2218
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2218
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2219
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2219
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2221
REMOVE AND INSTALL KDPF ASSEMBLY 2223
METHOD FOR REMOVING KDPF ASSEMBLY .2224
METHOD FOR INSTALLING KDPF ASSEMBLY .2227
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2231
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2231
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2235
REMOVE AND INSTALL SCR ASSEMBLY .2240
METHOD FOR REMOVING SCR ASSEMBLY 2240
METHOD FOR INSTALLING SCR ASSEMBLY 2241
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2244
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2244
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2254
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2264
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2264
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2265
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2267
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY .2267
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY .2269
REMOVE AND INSTALL KCCV ASSEMBLY 2271
METHOD FOR REMOVING KCCV ASSEMBLY .2271
METHOD FOR INSTALLING KCCV ASSEMBLY .2272
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2273
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2273
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2279
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2284
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2284
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2288
REMOVE AND INSTALL AdBlue/DEF PUMP 2293
METHOD FOR REMOVING AdBlue/DEF PUMP .2293
METHOD FOR INSTALLING AdBlue/DEF PUMP .2297
REMOVE AND INSTALL AdBlue/DEF HOSE 2301
METHOD FOR REMOVING AdBlue/DEF HOSE .2302
METHOD FOR INSTALLING AdBlue/DEF HOSE .2311
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2322
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2322
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2324
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2328
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2328
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2331
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2334
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2334
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2335
POWER TRAIN .2336
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2336
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2336
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2337
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2339
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2340
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2343
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2351
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2351
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2352
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2355
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2355
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2359
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2366
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2366
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2366
UNDERCARRIAGE AND FRAME .2368
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2368
METHOD FOR SEPARATING TRACK ASSEMBLY 2368
METHOD FOR INSTALLING TRACK ASSEMBLY 2369
REMOVE AND INSTALL SPROCKET .2372
METHOD FOR REMOVING SPROCKET 2372
METHOD FOR INSTALLING SPROCKET 2373
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2374
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2374
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2375
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2376
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2376
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2377
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2381
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2381
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2382
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2384
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2385
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2386
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2388
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2388
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2390
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2393
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2393
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2398
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE .2403
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE 2403
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE 2407
HYDRAULIC SYSTEM 2412
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2412
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2412
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2414
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2416
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2416
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2417
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2419
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2419
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2428
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2436
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2436
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2441
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2446
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2447
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2461
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2474
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2474
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2475
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2480
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2480
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2481
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2483
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2483
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2484
WORK EQUIPMENT 2486
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2486
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2486
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2489
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2492
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2493
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2495
CAB AND ITS ATTACHMENTS .2501
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2501
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2501
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2506
REMOVE AND INSTALL OPERATOR’S CAB DOOR 2511
METHOD FOR INSTALLING OPERATOR’S CAB DOOR .2512
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2516
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2517
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2518
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2529
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2529
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2531
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2537
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2537
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2543
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2549
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2549
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2554
REMOVE AND INSTALL OPERATOR’S SEAT 2559
METHOD FOR REMOVING OPERATOR’S SEAT .2559
METHOD FOR INSTALLING OPERATOR’S SEAT .2559
REMOVE AND INSTALL SEAT BELT 2561
METHOD FOR REMOVING SEAT BELT .2561
METHOD FOR INSTALLING SEAT BELT .2562
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2563
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2563
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2568
ELECTRICAL SYSTEM .2577
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2577
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2577
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2579
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2581
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2581
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2583
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2586
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2586
METHOD FOR INSTALLING KomVision CONTROLLER 2587
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2589
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2589
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2592
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2595
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2595
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2596
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2598
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2598
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2600
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2602
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2602
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2605
REMOVE AND INSTALL KomVision CAMERA .2608
METHOD FOR REMOVING KomVision CAMERA 2608
METHOD FOR INSTALLING KomVision CAMERA 2610
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2613
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2613
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2615
60 MAINTENANCE STANDARD .2617
CONTENTS 2618
ABBREVIATION LIST .2619
ENGINE AND COOLING SYSTEM .2625
MAINTENANCE STANDARD OF ENGINE MOUNT 2625
MAINTENANCE STANDARD OF COOLING SYSTEM 2626
POWER TRAIN .2628
MAINTENANCE STANDARD OF SWING CIRCLE 2628
MAINTENANCE STANDARD OF SWING MACHINERY .2629
MAINTENANCE STANDARD OF FINAL DRIVE .2631
MAINTENANCE STANDARD OF SPROCKET 2633
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2634
UNDERCARRIAGE AND FRAME .2636
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2636
MAINTENANCE STANDARD OF IDLER .2638
MAINTENANCE STANDARD OF TRACK ROLLER 2640
MAINTENANCE STANDARD OF CARRIER ROLLER 2642
MAINTENANCE STANDARD OF TRACK SHOE 2643
MAINTENANCE STANDARD OF TRIPLE SHOE .2646
MAINTENANCE STANDARD OF ROAD LINER 2647
MAINTENANCE STANDARD OF FLAT SHOE .2648
HYDRAULIC SYSTEM 2649
MAINTENANCE STANDARD OF HYDRAULIC TANK 2649
MAINTENANCE STANDARD OF MAIN PUMP .2650
MAINTENANCE STANDARD OF LS-EPC VALVE 2651
MAINTENANCE STANDARD OF PC-EPC VALVE 2652
MAINTENANCE STANDARD OF SWING MOTOR .2653
MAINTENANCE STANDARD OF TRAVEL MOTOR 2656
MAINTENANCE STANDARD OF CONTROL VALVE .2659
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2669
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2671
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2673
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2676
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2679
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2680
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2682
MAINTENANCE STANDARD OF SOLENOID VALVE 2684
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2685
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2686
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2687
WORK EQUIPMENT 2688
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2688
DIMENSION OF ARM 2693
DIMENSIONS OF BUCKET 2695
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2697
MAINTENANCE STANDARD OF ARM CYLINDER 2698
MAINTENANCE STANDARD OF BUCKET CYLINDER .2699
80 APPENDIX .2701
CONTENTS 2702
ABBREVIATION LIST .2704
AIR CONDITIONER SYSTEM 2710
PRECAUTIONS FOR REFRIGERANT .2710
AIR CONDITIONER COMPONENT .2711
SPECIFICATIONS OF AIR CONDITIONER .2713
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2714
OUTLINE OF REFRIGERATION CYCLE 2715
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2717
AIR CONDITIONER UNIT 2717
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2717
FUNCTION OF AIR CONDITIONER UNIT 2719
COMPONENT PARTS OF AIR CONDITIONER UNIT .2720
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2720
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2720
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2720
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2720
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2721
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2721
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2721
FUNCTION OF DUAL PRESSURE SWITCH 2722
AIR CONDITIONER CONTROLLER 2723
STRUCTURE OF AIR CONDITIONER CONTROLLER .2723
COMPRESSOR 2724
STRUCTURE OF COMPRESSOR .2724
SPECIFICATIONS OF COMPRESSOR 2724
FUNCTION OF COMPRESSOR 2724
CONDENSER .2725
STRUCTURE OF CONDENSER 2725
SPECIFICATIONS OF CONDENSER .2725
FUNCTION OF CONDENSER .2725
SENSORS FOR AIR CONDITIONER SYSTEM 2727
STRUCTURE OF SUNLIGHT SENSOR 2727
FUNCTION OF SUNLIGHT SENSOR .2727
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2727
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2727
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2729
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2731
AIR CONDITIONER SYSTEM DIAGRAM 2733
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2734
FUNCTION OF AIR CONDITIONER CONTROLLER 2735
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2736
TESTING AIR LEAKAGE (DUCT) 2745
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2745
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2747
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2748
TEST VENT (MODE) CHANGEOVER .2749
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2749
TESTING FRESH/RECIRC AIR CHANGEOVER .2750
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2750
TEST SUNLIGHT SENSOR 2751
METHOD FOR TESTING SUNLIGHT SENSOR 2751
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2752
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2752
TEST RELAYS .2754
METHOD FOR TESTING RELAYS .2754
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2755
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2757
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2760
FAILURE CODE [879AKA] .2762
FAILURE CODE [879AKB] .2763
FAILURE CODE [879BKA] .2764
FAILURE CODE [879BKB] .2766
FAILURE CODE [879CKA] .2768
FAILURE CODE [879CKB] .2769
FAILURE CODE [879DKZ] .2770
FAILURE CODE [879EMC] .2772
FAILURE CODE [879FMC] .2773
FAILURE CODE [879GKX] .2774
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2776
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2778
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2781
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2783
TROUBLESHOOTING USING GAUGE PRESSURE 2785
CONNECTION OF SERVICE TOOL 2787
METHOD FOR CONNECTING SERVICE TOOL 2787
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2789
HANDLE COMPRESSOR OIL .2791
METHOD FOR REPLACING DESICCANT 2793
90 CIRCUIT DIAGRAMS .2795
CONTENTS 2796
ABBREVIATION LIST .2797
HYDRAULIC CIRCUIT DIAGRAM .2803
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2803
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2807
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2809
ELECTRICAL CIRCUIT DIAGRAM 2811
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2811
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2815
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2817
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2819
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2821
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2823
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2825
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2827
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2829
INDEX 2831

DESCRIPTION:

Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00101 –  PDF DOWNLOAD

• SERIAL NUMBERS 5002 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams

G.B 30/12/24