Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00103 PDF

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Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00103  – PDF DOWNLOAD

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Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00103  – PDF DOWNLOAD

Language : English
Pages : 2866
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00103  – 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 . 150
FUNCTION OF BATTERY DISCONNECT SWITCH . 150
ENGINE SYSTEM . 151
LAYOUT DRAWING OF ENGINE SYSTEM . 151
SPECIFICATIONS OF ENGINE SYSTEM . 152
FUNCTION OF ENGINE SYSTEM . 152
ENGINE CONTROL SYSTEM . 153
ENGINE CONTROL SYSTEM DIAGRAM . 153
FUNCTION OF ENGINE CONTROL SYSTEM . 154
AUTO-DECELERATION SYSTEM 156
AUTO-DECELERATION SYSTEM DIAGRAM 156
FUNCTION OF AUTO-DECELERATION SYSTEM 156
OPERATION OF AUTO-DECELERATION SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM . 158
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 158
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 159
OVERHEAT PREVENTION SYSTEM 160
OVERHEAT PREVENTION SYSTEM DIAGRAM 160
FUNCTION OF OVERHEAT PREVENTION SYSTEM 161
TURBOCHARGER PROTECTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 163
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 165
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 165
COMPONENT PARTS OF ENGINE SYSTEM 168
VGT . 168
EGR SYSTEM 172
EGR VALVE . 174
EGR COOLER 176
KCCV SYSTEM . 177
KCCV VENTILATOR . 179
KDPF 181
COOLING SYSTEM 186
LAYOUT DRAWING OF COOLING SYSTEM 186
SPECIFICATIONS OF COOLING SYSTEM 187
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 188
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 188
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 189
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 190
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 190
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 190
COMPONENT PARTS OF COOLING SYSTEM . 192
FAN CLUTCH 192
CONTROL SYSTEM 193
LAYOUT DRAWING OF CONTROL SYSTEM 193
MACHINE MONITOR SYSTEM 196
MACHINE MONITOR SYSTEM DIAGRAM 196
FUNCTION OF MACHINE MONITOR SYSTEM 196
KomVision SYSTEM 198
LAYOUT DRAWING OF KomVision SYSTEM 198
KomVision SYSTEM DIAGRAM 200
FUNCTION OF KomVision SYSTEM 200
KOMTRAX SYSTEM 202
KOMTRAX SYSTEM DIAGRAM 202
FUNCTION OF KOMTRAX SYSTEM 202
COMPONENT PARTS OF CONTROL SYSTEM . 203
MACHINE MONITOR . 203
KomVision CONTROLLER 217
KomVision CAMERA 221
KOMTRAX TERMINAL 221
PUMP CONTROLLER . 224
RESISTOR FOR PC-EPC VALVE . 228
CAN TERMINATING RESISTOR 228
ENGINE CONTROLLER . 230
FUEL CONTROL DIAL . 236
HYDRAULIC SYSTEM 238
LAYOUT DRAWING OF HYDRAULIC SYSTEM 238
CLSS 242
STRUCTURE OF CLSS . 242
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 244
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 245
PRESSURE COMPENSATION CONTROL . 258
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 261
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 261
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 262
PUMP AND VALVE CONTROL SYSTEM . 267
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 267
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 268
COMPONENT PARTS OF HYDRAULIC SYSTEM . 270
HYDRAULIC TANK 270
MAIN PUMP . 272
CONTROL VALVE . 297
WORK EQUIPMENT SYSTEM . 355
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 355
ONE-TOUCH POWER MAXIMIZING SYSTEM . 360
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 360
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 361
PPC LOCK SYSTEM . 362
PPC LOCK SYSTEM DIAGRAM . 362
FUNCTION OF PPC LOCK SYSTEM . 362
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 363
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 363
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 363
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 364
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 365
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 365
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 366
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 367
WORK EQUIPMENT AND SWING PPC VALVE 367
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 372
2ND-LINE ATTACHMENT PPC VALVE . 377
SOLENOID VALVE 379
ANTI-DROP VALVE FOR BOOM 383
ANTI-DROP VALVE FOR ARM . 387
BOOM ANGLE POTENTIOMETER 391
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 392
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 394
PILOT CIRCUIT ACCUMULATOR . 396
ATTACHMENT CIRCUIT ACCUMULATOR 397
SWING SYSTEM 398
LAYOUT DRAWING OF SWING SYSTEM 398
SWING CONTROL SYSTEM DIAGRAM 402
FUNCTION OF SWING CONTROL SYSTEM 402
COMPONENT PARTS OF SWING SYSTEM . 406
SWING MOTOR . 406
SWING MACHINERY . 417
SWING CIRCLE 418
TRAVEL SYSTEM . 420
LAYOUT DRAWING OF TRAVEL SYSTEM . 420
TRAVEL CONTROL SYSTEM DIAGRAM . 424
FUNCTION OF TRAVEL CONTROL SYSTEM . 424
COMPONENT PARTS OF TRAVEL SYSTEM 426
TRAVEL MOTOR 426
FINAL DRIVE . 438
TRAVEL PPC VALVE 440
CENTER SWIVEL JOINT . 445
UNDERCARRIAGE AND FRAME . 447
LAYOUT DRAWING OF UNDERCARRIAGE . 447
SPECIFICATIONS OF UNDERCARRIAGE . 448
WORK EQUIPMENT 449
STRUCTURE OF WORK EQUIPMENT . 449
FUNCTION OF WORK EQUIPMENT 450
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 451
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 451
BUCKET CLEARANCE ADJUSTMENT SHIM 452
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 452
CAB AND ITS ATTACHMENTS . 453
ROPS CAB 453
STRUCTURE OF ROPS CAB . 453
FUNCTION OF ROPS CAB 453
CAB MOUNT . 454
STRUCTURE OF CAB MOUNT 454
FUNCTION OF CAB MOUNT . 454
CAB TIPPING STOPPER . 455
STRUCTURE OF CAB TIPPING STOPPER 455
FUNCTION OF CAB TIPPING STOPPER . 455
TAKE WIRING HARNESS OUT OF CAB 456
20 STANDARD VALUE TABLE . 457
CONTENTS 458
ABBREVIATION LIST . 459
STANDARD VALUE TABLE FOR ENGINE . 465
STANDARD VALUE TABLE FOR ENGINE: PC228USLC-11 . 465
STANDARD VALUE TABLE FOR MACHINE 470
STANDARD VALUE TABLE FOR MACHINE: PC228USLC-11 470
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 484
30 TESTING AND ADJUSTING 489
CONTENTS 490
ABBREVIATION LIST . 493
RELATED INFORMATION ON TESTING AND ADJUSTING 499
TOOLS FOR TESTING AND ADJUSTING . 499
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 506
ENGINE AND COOLING SYSTEM . 508
TEST ENGINE SPEED . 508
METHOD FOR TESTING ENGINE SPEED . 508
TEST BOOST PRESSURE . 511
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 511
METHOD FOR TESTING BOOST PRESSURE . 512
TEST EXHAUST GAS COLOR 514
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 514
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 515
TEST AND ADJUST VALVE CLEARANCE . 517
METHOD FOR TESTING VALVE CLEARANCE 517
METHOD FOR ADJUSTING VALVE CLEARANCE 518
TEST COMPRESSION PRESSURE . 520
METHOD FOR TESTING COMPRESSION PRESSURE . 520
TEST BLOWBY PRESSURE 525
METHOD FOR TESTING BLOWBY PRESSURE 525
TEST ENGINE OIL PRESSURE 527
METHOD FOR TESTING ENGINE OIL PRESSURE 527
TEST EGR VALVE AND VGT OIL PRESSURE . 528
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 528
TEST FUEL PRESSURE 530
METHOD FOR TESTING FUEL PRESSURE 531
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 536
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 537
BLEEDING AIR FROM FUEL SYSTEM . 543
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 543
TEST FUEL CIRCUIT FOR LEAKAGE . 544
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 544
HANDLE CYLINDER CUT-OUT MODE OPERATION 546
HANDLE NO-INJECTION CRANKING OPERATION 547
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 548
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 548
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 548
TEST COOLING FAN SPEED 550
METHOD FOR TESTING COOLING FAN SPEED 550
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 551
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 551
TEST SCR RELATED FUNCTIONS 552
TEST AdBlue/DEF PUMP RAISED PRESSURE 555
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 558
TEST AdBlue/DEF LINE HEATER RELAY 1 . 562
TEST AdBlue/DEF LINE HEATER RELAY 2 . 565
TEST AdBlue/DEF PUMP HEATER RELAY . 567
TEST AdBlue/DEF TANK HEATER VALVE . 571
TEST DENITRATION EFFICIENCY OF SCR 573
CLEAN AdBlue/DEF TANK . 578
METHOD FOR CLEANING AdBlue/DEF TANK . 578
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 582
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 582
POWER TRAIN . 584
TEST SWING CIRCLE BEARING CLEARANCE . 584
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 584
UNDERCARRIAGE AND FRAME . 585
TEST AND ADJUST TRACK TENSION . 585
METHOD FOR TESTING TRACK TENSION 585
METHOD FOR ADJUSTING TRACK TENSION 585
HYDRAULIC SYSTEM 587
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 587
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 587
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 587
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 591
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 592
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 593
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 594
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 602
TEST OIL PRESSURE OF CONTROL CIRCUIT 604
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 604
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 606
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 606
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE . 607
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 608
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 610
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 610
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 612
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 613
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 614
METHOD FOR ADJUSTING LS VALVE . 615
TEST OUTLET PRESSURE OF SOLENOID VALVE 616
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 616
OPERATING CONDITION OF SOLENOID VALVE . 617
TEST PPC VALVE OUTLET PRESSURE 620
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 620
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 623
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 623
TEST PUMP SWASH PLATE SENSOR 624
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 624
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 625
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 625
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 626
METHOD FOR TESTING OF THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM LOCK VALVE 626
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 626
TEST OIL LEAKAGE 628
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 628
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 628
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 629
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 629
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 630
BLEED AIR FROM HYDRAULIC CIRCUIT 631
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 633
WORK EQUIPMENT 635
ADJUST BOOM ANGLE POTENTIOMETER . 635
METHOD FOR ADJUSTING BOOM ANGLE POTENTIOMETER . 635
CAB AND ITS ATTACHMENTS . 636
TEST CAB TIPPING STOPPER 636
METHOD FOR TESTING CAB TIPPING STOPPER 636
METHOD FOR ADJUSTING MIRRORS 637
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 637
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 638
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 639
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 640
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (C) 641
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (C) 641
PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (D) . 643
ELECTRICAL SYSTEM . 644
SET AND OPERATE MACHINE MONITOR . 644
OPERATOR MODE . 647
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 647
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 648
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 648
CHECKING FUNCTION OF SERVICE METER 649
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 649
SERVICE MODE 651
METHOD FOR OPERATING SERVICE MODE . 651
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 654
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 661
ABNORMALITY RECORD MENU . 672
METHOD FOR CONFIRMING MAINTENANCE RECORD 677
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 678
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 682
DEFAULT MENU 683
DIAGNOSTIC TESTS MENU . 691
ADJUSTMENT MENU . 700
METHOD FOR PERFORMING NO-INJECTION CRANKING . 721
KOMTRAX SETTINGS MENU . 722
METHOD FOR DISPLAYING SERVICE MESSAGE . 725
METHOD FOR STARTING UP KOMTRAX TERMINAL . 727
ADJUST REARVIEW CAMERA ANGLE 732
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 732
ADJUST KomVision CAMERA ANGLE . 734
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 735
ADJUST KomVision RELATED ITEMS 737
SETTING OF KomVision (MAIN SETTING) . 737
SETTING OF KomVision (CAMERA SETTING) . 739
SETTING OF KomVision (CAMERA CALIBRATION) . 741
KomVision screen – Check 12 m visibility 754
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 757
HANDLE BATTERY DISCONNECT SWITCH 758
TEST DIODES . 759
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 759
METHOD FOR TESTING DIODE USING ANALOG TESTER 759
Pm CLINIC . 760
Pm CLINIC SERVICE . 760
Pm CLINIC CHECK SHEET: PC228USLC-11 . 761
40 TROUBLESHOOTING 771
CONTENTS 772
ABBREVIATION LIST . 783
RELATED INFORMATION ON TROUBLESHOOTING 789
GENERAL TROUBLESHOOTING POINTS 789
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 790
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 802
CHECKS BEFORE TROUBLESHOOTING . 804
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 806
WALK-AROUND CHECK . 806
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 808
CHECK FUEL LEVEL AND TYPE . 808
CHECK IMPURE INGREDIENT IN FUEL . 808
CHECK FUEL PREFILTER 809
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 809
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 810
CHECK MAIN FILTER . 811
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 813
CHECK COOLANT LEVEL (RESERVOIR TANK) 814
CHECK CLOGGING OF AIR CLEANER . 814
OUTER ELEMENT – CLEAN . 815
ELEMENTS – REPLACE 817
CHECK HYDRAULIC OIL LEVEL . 818
CHECK HYDRAULIC OIL STRAINER 819
CHECK HYDRAULIC FILTER 820
CHECK OIL LEVEL IN SWING MACHINERY CASE . 821
CHECK OIL LEVEL IN DAMPER CASE 822
CHECK OIL LEVEL IN FINAL DRIVE CASE . 822
BLEED AIR FROM FUEL SYSTEM 823
BLEED AIR FROM HYDRAULIC SYSTEM . 823
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 823
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 829
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 829
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 829
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 830
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 831
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 832
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 832
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 836
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 839
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 843
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 845
CONNECTORS LIST AND LAYOUT 848
CONNECTOR CONTACT IDENTIFICATION 862
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 902
FUSE LOCATION TABLE . 908
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 911
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 915
FAILURE CODES TABLE . 917
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 935
FAILURE CODE [879AKA] . 935
FAILURE CODE [879AKB] . 936
FAILURE CODE [879BKA] . 937
FAILURE CODE [879BKB] . 939
FAILURE CODE [879CKA] . 941
FAILURE CODE [879CKB] . 942
FAILURE CODE [879DKZ] . 943
FAILURE CODE [879EMC] . 945
FAILURE CODE [879FMC] . 946
FAILURE CODE [879GKX] . 947
FAILURE CODE [989L00] . 949
FAILURE CODE [989M00] . 950
FAILURE CODE [989N00] . 951
FAILURE CODE [A1U0N3] . 952
FAILURE CODE [A1U0N4] . 954
FAILURE CODE [A900FR] . 956
FAILURE CODE [A900N6] . 957
FAILURE CODE [A900NY] . 958
FAILURE CODE [AA10NX] . 959
FAILURE CODE [AB00KE] . 961
FAILURE CODE [AQ10N3] . 963
FAILURE CODE [AS00N3] . 965
FAILURE CODE [AS00R2] . 967
FAILURE CODE [AS00R3] . 968
FAILURE CODE [AS00R4] . 969
FAILURE CODE [AS00R5] . 970
FAILURE CODE [AS00R6] . 971
FAILURE CODE [AS00ZK] . 972
FAILURE CODE [AS10KM] . 973
FAILURE CODE [AS10NR] . 974
FAILURE CODE [AS10NT] . 975
FAILURE CODE [B@BAZG] . 976
FAILURE CODE [B@BAZK] . 978
FAILURE CODE [B@BCNS] . 980
FAILURE CODE [B@BCQA] . 982
FAILURE CODE [B@BCZK] . 984
FAILURE CODE [B@HANS] . 986
FAILURE CODE [CA115] 988
FAILURE CODE [CA122] 993
FAILURE CODE [CA123] 996
FAILURE CODE [CA131] 998
FAILURE CODE [CA132] 1000
FAILURE CODE [CA144] 1002
FAILURE CODE [CA145] 1004
FAILURE CODE [CA153] 1006
FAILURE CODE [CA154] 1008
FAILURE CODE [CA187] 1010
FAILURE CODE [CA221] 1012
FAILURE CODE [CA222] 1014
FAILURE CODE [CA227] 1016
FAILURE CODE [CA234] 1017
FAILURE CODE [CA238] 1018
FAILURE CODE [CA239] 1019
FAILURE CODE [CA249] 1020
FAILURE CODE [CA256] 1022
FAILURE CODE [CA271] 1024
FAILURE CODE [CA272] 1026
FAILURE CODE [CA322] 1028
FAILURE CODE [CA323] 1030
FAILURE CODE [CA324] 1032
FAILURE CODE [CA325] 1034
FAILURE CODE [CA331] 1036
FAILURE CODE [CA332] 1038
FAILURE CODE [CA343] 1040
FAILURE CODE [CA351] 1042
FAILURE CODE [CA352] 1044
FAILURE CODE [CA356] 1046
FAILURE CODE [CA357] 1048
FAILURE CODE [CA386] 1050
FAILURE CODE [CA428] 1052
FAILURE CODE [CA429] 1054
FAILURE CODE [CA435] 1056
FAILURE CODE [CA441] 1058
FAILURE CODE [CA442] 1060
FAILURE CODE [CA449] 1061
FAILURE CODE [CA451] 1062
FAILURE CODE [CA452] 1064
FAILURE CODE [CA488] 1066
FAILURE CODE [CA515] 1069
FAILURE CODE [CA516] 1071
FAILURE CODE [CA553] 1073
FAILURE CODE [CA555] 1074
FAILURE CODE [CA556] 1076
FAILURE CODE [CA559] 1078
FAILURE CODE [CA595] 1081
FAILURE CODE [CA687] 1083
FAILURE CODE [CA689] 1085
FAILURE CODE [CA691] 1088
FAILURE CODE [CA692] 1090
FAILURE CODE [CA697] 1092
FAILURE CODE [CA698] 1093
FAILURE CODE [CA731] 1094
FAILURE CODE [CA778] 1096
FAILURE CODE [CA1117] .1101
FAILURE CODE [CA1664] .1102
FAILURE CODE [CA1669] .1105
FAILURE CODE [CA1673] .1106
FAILURE CODE [CA1677] .1107
FAILURE CODE [CA1678] .1108
FAILURE CODE [CA1682] .1109
FAILURE CODE [CA1683] .1113
FAILURE CODE [CA1684] .1115
FAILURE CODE [CA1686] .1117
FAILURE CODE [CA1691] .1118
FAILURE CODE [CA1694] .1121
FAILURE CODE [CA1695] .1124
FAILURE CODE [CA1696] .1126
FAILURE CODE [CA1712] .1128
FAILURE CODE [CA1713] .1131
FAILURE CODE [CA1714] .1134
FAILURE CODE [CA1715] .1135
FAILURE CODE [CA1776] .1136
FAILURE CODE [CA1777] .1139
FAILURE CODE [CA1843] .1142
FAILURE CODE [CA1844] .1144
FAILURE CODE [CA1879] .1146
FAILURE CODE [CA1881] .1148
FAILURE CODE [CA1883] .1150
FAILURE CODE [CA1885] .1154
FAILURE CODE [CA1887] .1156
FAILURE CODE [CA1921] .1158
FAILURE CODE [CA1922] .1161
FAILURE CODE [CA1942] .1166
FAILURE CODE [CA1993] .1168
FAILURE CODE [CA2185] .1170
FAILURE CODE [CA2186] .1171
FAILURE CODE [CA2249] .1173
FAILURE CODE [CA2271] .1176
FAILURE CODE [CA2272] .1178
FAILURE CODE [CA2288] .1180
FAILURE CODE [CA2311] .1182
FAILURE CODE [CA2349] .1184
FAILURE CODE [CA2353] .1186
FAILURE CODE [CA2357] .1188
FAILURE CODE [CA2381] .1191
FAILURE CODE [CA2382] .1193
FAILURE CODE [CA2383] .1196
FAILURE CODE [CA2386] .1198
FAILURE CODE [CA2387] .1200
FAILURE CODE [CA2555] .1203
FAILURE CODE [CA2556] .1205
FAILURE CODE [CA2637] .1207
FAILURE CODE [CA2639] .1209
FAILURE CODE [CA2771] .1211
FAILURE CODE [CA2777] .1216
FAILURE CODE [CA2976] .1219
FAILURE CODE [CA3133] .1221
FAILURE CODE [CA3134] .1223
FAILURE CODE [CA3135] .1225
FAILURE CODE [CA3142] .1228
FAILURE CODE [CA3143] .1229
FAILURE CODE [CA3144] .1230
FAILURE CODE [CA3146] .1233
FAILURE CODE [CA3147] .1234
FAILURE CODE [CA3148] .1235
FAILURE CODE [CA3151] .1238
FAILURE CODE [CA3165] .1244
FAILURE CODE [CA3229] .1247
FAILURE CODE [CA3231] .1250
FAILURE CODE [CA3232] .1253
FAILURE CODE [CA3235] .1258
FAILURE CODE [CA3239] .1261
FAILURE CODE [CA3241] .1264
FAILURE CODE [CA3242] .1266
FAILURE CODE [CA3251] .1269
FAILURE CODE [CA3253] .1271
FAILURE CODE [CA3254] .1275
FAILURE CODE [CA3255] .1279
FAILURE CODE [CA3256] .1282
FAILURE CODE [CA3311] .1285
FAILURE CODE [CA3312] .1288
FAILURE CODE [CA3313] .1291
FAILURE CODE [CA3314] .1292
FAILURE CODE [CA3315] .1293
FAILURE CODE [CA3316] .1295
FAILURE CODE [CA3317] .1296
FAILURE CODE [CA3318] .1297
FAILURE CODE [CA3319] .1300
FAILURE CODE [CA3321] .1302
FAILURE CODE [CA3322] .1304
FAILURE CODE [CA3419] .1306
FAILURE CODE [CA3421] .1308
FAILURE CODE [CA3497] .1310
FAILURE CODE [CA3498] .1311
FAILURE CODE [CA3543] .1312
FAILURE CODE [CA3545] .1318
FAILURE CODE [CA3547] .1320
FAILURE CODE [CA3558] .1321
FAILURE CODE [CA3559] .1323
FAILURE CODE [CA3562] .1325
FAILURE CODE [CA3563] .1327
FAILURE CODE [CA3567] .1330
FAILURE CODE [CA3568] .1333
FAILURE CODE [CA3571] .1338
FAILURE CODE [CA3572] .1340
FAILURE CODE [CA3574] .1342
FAILURE CODE [CA3575] .1345
FAILURE CODE [CA3577] .1347
FAILURE CODE [CA3578] .1349
FAILURE CODE [CA3582] .1351
FAILURE CODE [CA3583] .1359
FAILURE CODE [CA3596] .1361
FAILURE CODE [CA3649] .1366
FAILURE CODE [CA3681] .1369
FAILURE CODE [CA3682] .1374
FAILURE CODE [CA3713] .1379
FAILURE CODE [CA3717] .1382
FAILURE CODE [CA3718] .1383
FAILURE CODE [CA3725] .1384
FAILURE CODE [CA3741] .1387
FAILURE CODE [CA3748] .1388
FAILURE CODE [CA3751] .1390
FAILURE CODE [CA3755] .1392
FAILURE CODE [CA3866] .1394
FAILURE CODE [CA3867] .1398
FAILURE CODE [CA3868] .1401
FAILURE CODE [CA3899] .1406
FAILURE CODE [CA3911] .1408
FAILURE CODE [CA3912] .1413
FAILURE CODE [CA3932] .1415
FAILURE CODE [CA3933] .1417
FAILURE CODE [CA3934] .1419
FAILURE CODE [CA3935] .1422
FAILURE CODE [CA3936] .1424
FAILURE CODE [CA4151] .1426
FAILURE CODE [CA4152] .1432
FAILURE CODE [CA4155] .1437
FAILURE CODE [CA4156] .1439
FAILURE CODE [CA4157] .1442
FAILURE CODE [CA4158] .1444
FAILURE CODE [CA4159] .1445
FAILURE CODE [CA4161] .1446
FAILURE CODE [CA4162] .1449
FAILURE CODE [CA4163] .1452
FAILURE CODE [CA4164] .1453
FAILURE CODE [CA4165] .1455
FAILURE CODE [CA4166] .1457
FAILURE CODE [CA4168] .1459
FAILURE CODE [CA4169] .1463
FAILURE CODE [CA4171] .1467
FAILURE CODE [CA4249] .1471
FAILURE CODE [CA4251] .1475
FAILURE CODE [CA4259] .1479
FAILURE CODE [CA4261] .1482
FAILURE CODE [CA4277] .1485
FAILURE CODE [CA4281] .1488
FAILURE CODE [CA4459] .1491
FAILURE CODE [CA4461] .1493
FAILURE CODE [CA4658] .1496
FAILURE CODE [CA4731] .1499
FAILURE CODE [CA4732] .1500
FAILURE CODE [CA4739] .1501
FAILURE CODE [CA4768] .1502
FAILURE CODE [CA4769] .1504
FAILURE CODE [CA4842] .1507
FAILURE CODE [CA4952] .1510
FAILURE CODE [CA5115] .1512
FAILURE CODE [CA5179] .1515
FAILURE CODE [CA5181] .1517
FAILURE CODE [CA5383] .1519
FAILURE CODE [D110KB] .1521
FAILURE CODE [D19JKZ] .1523
FAILURE CODE [D811MC] .1526
FAILURE CODE [D862KA] .1527
FAILURE CODE [D8ALKA] .1528
FAILURE CODE [D8ALKB] .1530
FAILURE CODE [D8AQKR] .1532
FAILURE CODE [DA20MC] .1536
FAILURE CODE [DA22KK] .1537
FAILURE CODE [DA25KP] .1540
FAILURE CODE [DA29KQ] .1543
FAILURE CODE [DA2LKA] .1546
FAILURE CODE [DA2LKB] .1548
FAILURE CODE [DA2QKR] .1550
FAILURE CODE [DA2RKR] .1555
FAILURE CODE [DAF0KM] .1560
FAILURE CODE [DAF0MB] .1561
FAILURE CODE [DAF0MC] .1562
FAILURE CODE [DAF8KB] .1563
FAILURE CODE [DAF9KQ] .1565
FAILURE CODE [DAFGMC] .1566
FAILURE CODE [DAFLKA] .1567
FAILURE CODE [DAFLKB] .1569
FAILURE CODE [DAFQKR] .1571
FAILURE CODE [DAZ9KQ] .1575
FAILURE CODE [DAZQKR] .1576
FAILURE CODE [DB2QKR] .1580
FAILURE CODE [DB2RKR] .1585
FAILURE CODE [DBP0KM] .1591
FAILURE CODE [DBP0KT] .1592
FAILURE CODE [DBP5KB] .1593
FAILURE CODE [DBP5KY] .1595
FAILURE CODE [DBPQKR] .1597
FAILURE CODE [DDNRKA] .1602
FAILURE CODE [DDNRKY] .1604
FAILURE CODE [DDNS00] .1606
FAILURE CODE [DFB1KZ] .1608
FAILURE CODE [DFB2KZ] .1610
FAILURE CODE [DFB3L8] .1612
FAILURE CODE [DFB4L8] .1614
FAILURE CODE [DFB5KZ] .1616
FAILURE CODE [DFB6KZ] .1618
FAILURE CODE [DGH2KA] .1620
FAILURE CODE [DGH2KB] .1622
FAILURE CODE [DHA4KA] .1624
FAILURE CODE [DHAAMA] .1626
FAILURE CODE [DHACMA] .1628
FAILURE CODE [DHPAMA] .1630
FAILURE CODE [DHPBMA] .1632
FAILURE CODE [DHS3MA] .1634
FAILURE CODE [DHS4MA] .1636
FAILURE CODE [DHS8MA] .1638
FAILURE CODE [DHS9MA] .1640
FAILURE CODE [DHSAMA] .1642
FAILURE CODE [DHSBMA] .1644
FAILURE CODE [DHSCMA] .1646
FAILURE CODE [DHSDMA] .1648
FAILURE CODE [DHSFMA] .1650
FAILURE CODE [DHSGMA] .1652
FAILURE CODE [DHSHMA] .1654
FAILURE CODE [DHSJMA] .1656
FAILURE CODE [DHX1MA] .1658
FAILURE CODE [DKR0MA] .1659
FAILURE CODE [DKR1MA] .1662
FAILURE CODE [DKULKA] .1665
FAILURE CODE [DKULKB] .1667
FAILURE CODE [DKULKY] .1669
FAILURE CODE [DLM5KA] .1671
FAILURE CODE [DLM5MB] .1673
FAILURE CODE [DR10KA] .1676
FAILURE CODE [DR12KA] .1679
FAILURE CODE [DR20KA] .1681
FAILURE CODE [DR21KX] .1683
FAILURE CODE [DR31KX] .1685
FAILURE CODE [DR40KA] .1687
FAILURE CODE [DUMBKA] .1689
FAILURE CODE [DUMBKB] .1691
FAILURE CODE [DV20KB] .1693
FAILURE CODE [DW43KA] .1695
FAILURE CODE [DW43KB] .1697
FAILURE CODE [DW43KY] .1699
FAILURE CODE [DW45KA] .1701
FAILURE CODE [DW45KB] .1704
FAILURE CODE [DW45KY] .1707
FAILURE CODE [DW4CKY] .1709
FAILURE CODE [DW4GKA] .1711
FAILURE CODE [DW91KA] .1713
FAILURE CODE [DW91KB] .1715
FAILURE CODE [DW91KY] .1717
FAILURE CODE [DWA2KA] .1719
FAILURE CODE [DWA2KB] .1721
FAILURE CODE [DWA2KY] .1723
FAILURE CODE [DWK0KA] .1725
FAILURE CODE [DWK0KB] .1727
FAILURE CODE [DWK0KY] .1729
FAILURE CODE [DWK2KA] .1731
FAILURE CODE [DWK2KB] .1733
FAILURE CODE [DWK2KY] .1735
FAILURE CODE [DWK8KA] .1737
FAILURE CODE [DWK8KB] .1739
FAILURE CODE [DWK8KY] .1741
FAILURE CODE [DWN5KY] .1743
FAILURE CODE [DXA8KA] .1745
FAILURE CODE [DXA8KB] .1747
FAILURE CODE [DXA9KA] .1749
FAILURE CODE [DXA9KB] .1751
FAILURE CODE [DXE0KA] .1753
FAILURE CODE [DXE0KB] .1755
FAILURE CODE [DXE4KA] .1757
FAILURE CODE [DXE4KB] .1759
FAILURE CODE [DXE4KY] .1761
FAILURE CODE [DXE5KA] .1763
FAILURE CODE [DXE5KB] .1765
FAILURE CODE [DXE6KA] .1767
FAILURE CODE [DXE6KB] .1769
FAILURE CODE [DXE7KA] .1771
FAILURE CODE [DXE7KB] .1773
FAILURE CODE [DXE7KY] .1775
FAILURE CODE [DXE8KA] .1777
FAILURE CODE [DXE8KB] .1779
FAILURE CODE [DXE8KY] .1781
FAILURE CODE [DXE9KA] .1783
FAILURE CODE [DXE9KB] .1785
FAILURE CODE [DXE9KY] .1787
FAILURE CODE [DXEAKA] .1789
FAILURE CODE [DXEAKB] .1791
FAILURE CODE [DXEAKY] .1793
FAILURE CODE [DY20KA] .1795
FAILURE CODE [DY20MA] .1797
FAILURE CODE [DY2CKB] .1799
FAILURE CODE [DY2DKB] .1801
FAILURE CODE [DY2EKB] .1803
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1805
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1805
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1811
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1814
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1816
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1818
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1821
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1822
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1823
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1824
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1825
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1826
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1827
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1828
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1829
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1830
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1831
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1832
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1834
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1835
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1836
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1837
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1839
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1840
E-24 FUNCTION SWITCH DOES NOT OPERATE .1841
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1842
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1843
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1844
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1845
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1846
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1847
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1848
E-32 ALARM BUZZER CANNOT BE CANCELED 1850
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1851
E-34 SERVICE MODE CANNOT BE SELECTED 1852
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1853
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1856
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1858
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1861
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1863
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1865
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1866
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1868
E-43 HORN DOES NOT SOUND 1869
E-44 HORN DOES NOT STOP SOUNDING 1872
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1874
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1875
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1877
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1878
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1879
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1880
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1881
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1882
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1883
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1884
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1885
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1886
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1888
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1890
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1891
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1891
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1892
FAILURE MODE AND CAUSE TABLE 1894
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1903
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1904
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1907
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1908
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1909
H-6 SPEED OR POWER OF BOOM IS LOW .1911
H-7 ARM SPEED OR POWER IS LOW .1916
H-8 BUCKET SPEED OR POWER IS LOW 1921
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1924
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1925
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1927
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1929
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1930
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1931
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1932
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1933
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1934
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1935
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1936
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1937
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1938
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1940
H-23 TRAVEL SPEED IS LOW 1943
H-24 ONE OF TRACKS DOES NOT RUN .1945
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1946
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1947
H-27 SWINGS ONLY IN ONE DIRECTION .1948
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1949
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1950
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1951
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1952
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1953
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1954
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1955
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1956
H-1 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1957
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1958
TROUBLESHOOTING OF ENGINE (S-MODE) 1959
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1959
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1960
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1961
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1962
S-4 ENGINE STARTABILITY IS POOR .1964
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1966
S-6 ENGINE STOPS DURING OPERATION .1968
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1970
S-8 ENGINE LACKS POWER 1971
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1973
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1975
S-11 OIL BECOMES CONTAMINATED QUICKLY .1976
S-12 FUEL CONSUMPTION IS EXCESSIVE 1977
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1978
S-14 OIL PRESSURE DROPS .1979
S-15 FUEL MIXES INTO ENGINE OIL .1981
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1982
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1983
S-18 UNUSUAL NOISE IS HEARD .1984
S-19 VIBRATION IS EXCESSIVE .1985
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1986
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1987
S-22 ACTIVE REGENERATION TAKES TIME .1989
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1990
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1991
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1993
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1994
50 DISASSEMBLY AND ASSEMBLY .1995
CONTENTS 1996
ABBREVIATION LIST .2001
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2007
HOW TO READ THIS MANUAL .2007
COATING MATERIALS LIST 2009
SPECIAL TOOLS LIST 2013
SKETCHES OF SPECIAL TOOLS .2032
ENGINE AND COOLING SYSTEM .2038
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2038
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2038
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2041
REMOVE AND INSTALL INJECTOR ASSEMBLY 2044
METHOD FOR REMOVING INJECTOR ASSEMBLY .2045
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2050
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2060
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2061
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2070
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2086
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2086
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2087
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2089
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2089
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2092
REMOVE AND INSTALL STARTER ASSEMBLY .2096
METHOD FOR REMOVING STARTER ASSEMBLY 2096
METHOD FOR INSTALLING STARTER ASSEMBLY 2098
REMOVE AND INSTALL ALTERNATOR BELT 2101
METHOD FOR REMOVING ALTERNATOR BELT .2101
METHOD FOR INSTALLING ALTERNATOR BELT .2104
REMOVE AND INSTALL RADIATOR ASSEMBLY 2107
METHOD FOR REMOVING RADIATOR ASSEMBLY .2107
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2110
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2114
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2114
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2121
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2128
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2128
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2130
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2132
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2132
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2137
REMOVE AND INSTALL ENGINE ASSEMBLY 2142
METHOD FOR REMOVING ENGINE ASSEMBLY .2142
METHOD FOR INSTALLING ENGINE ASSEMBLY .2152
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2164
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2164
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2169
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2174
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2174
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2175
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2178
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2178
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2180
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2182
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2182
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2183
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2185
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2185
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2191
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2198
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2199
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2206
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2212
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2213
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2220
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2225
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2225
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2226
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2228
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2228
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2228
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2229
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2229
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2231
REMOVE AND INSTALL KDPF ASSEMBLY 2233
METHOD FOR REMOVING KDPF ASSEMBLY .2234
METHOD FOR INSTALLING KDPF ASSEMBLY .2237
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2241
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2241
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2245
REMOVE AND INSTALL SCR ASSEMBLY .2250
METHOD FOR REMOVING SCR ASSEMBLY 2250
METHOD FOR INSTALLING SCR ASSEMBLY 2251
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2254
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2254
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2264
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2274
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2274
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2275
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2277
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY .2277
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY .2279
REMOVE AND INSTALL KCCV ASSEMBLY 2281
METHOD FOR REMOVING KCCV ASSEMBLY .2281
METHOD FOR INSTALLING KCCV ASSEMBLY .2282
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2283
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2283
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2289
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2294
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2294
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2298
REMOVE AND INSTALL AdBlue/DEF PUMP 2303
METHOD FOR REMOVING AdBlue/DEF PUMP .2303
METHOD FOR INSTALLING AdBlue/DEF PUMP .2307
REMOVE AND INSTALL AdBlue/DEF HOSE 2311
METHOD FOR REMOVING AdBlue/DEF HOSE .2312
METHOD FOR INSTALLING AdBlue/DEF HOSE .2322
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2332
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2332
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2334
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2338
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2338
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2341
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2344
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2344
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2345
POWER TRAIN .2346
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2346
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2346
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2347
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2348
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2349
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2352
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2360
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2360
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2361
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2364
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2364
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2368
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2375
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2375
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2375
UNDERCARRIAGE AND FRAME .2377
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2377
METHOD FOR SEPARATING TRACK ASSEMBLY 2377
METHOD FOR INSTALLING TRACK ASSEMBLY 2378
REMOVE AND INSTALL SPROCKET .2381
METHOD FOR REMOVING SPROCKET 2381
METHOD FOR INSTALLING SPROCKET 2382
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2383
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2383
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2384
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2385
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2385
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2386
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2390
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2390
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2391
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2393
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2393
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2394
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2397
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2397
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2399
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2402
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2402
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2407
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE .2412
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE 2412
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE 2416
HYDRAULIC SYSTEM 2421
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2421
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2421
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2423
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2425
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2425
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2426
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2428
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2428
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2437
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2445
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2445
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2450
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2455
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2456
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2470
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2483
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2483
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2484
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2489
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2489
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2490
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2492
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2492
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2493
WORK EQUIPMENT 2495
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2495
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2495
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2498
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2501
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2502
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2504
CAB AND ITS ATTACHMENTS .2510
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2510
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2510
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2516
REMOVE AND INSTALL OPERATOR’S CAB DOOR 2523
INSTALL OPERATOR’S CAB DOOR .2524
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2528
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2529
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2530
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2539
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2539
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2541
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2547
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2547
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2553
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2559
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2559
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2565
REMOVE AND INSTALL OPERATOR’S SEAT 2572
METHOD FOR REMOVING OPERATOR’S SEAT .2572
METHOD FOR INSTALLING OPERATOR’S SEAT .2573
REMOVE AND INSTALL SEAT BELT 2574
METHOD FOR REMOVING SEAT BELT .2574
METHOD FOR INSTALLING SEAT BELT .2575
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2576
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2576
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2581
ELECTRICAL SYSTEM .2590
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2590
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2590
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2592
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2594
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2594
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2597
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2600
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2600
METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY .2602
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2604
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2604
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2607
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2611
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2611
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2612
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2614
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2614
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2616
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2618
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2618
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2621
REMOVE AND INSTALL KomVision CAMERA .2624
METHOD FOR REMOVING KomVision CAMERA 2624
METHOD FOR INSTALLING KomVision CAMERA 2626
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2629
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2629
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2631
60 MAINTENANCE STANDARD .2633
CONTENTS 2634
ABBREVIATION LIST .2635
ENGINE AND COOLING SYSTEM .2641
MAINTENANCE STANDARD OF ENGINE MOUNT 2641
MAINTENANCE STANDARD OF COOLING SYSTEM 2642
POWER TRAIN .2644
MAINTENANCE STANDARD OF SWING CIRCLE 2644
MAINTENANCE STANDARD OF SWING MACHINERY .2645
MAINTENANCE STANDARD OF FINAL DRIVE .2647
MAINTENANCE STANDARD OF SPROCKET 2649
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2650
UNDERCARRIAGE AND FRAME .2652
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2652
MAINTENANCE STANDARD OF IDLER .2654
MAINTENANCE STANDARD OF TRACK ROLLER 2656
MAINTENANCE STANDARD OF CARRIER ROLLER 2658
MAINTENANCE STANDARD OF TRACK SHOE 2659
MAINTENANCE STANDARD OF TRIPLE SHOE .2662
MAINTENANCE STANDARD OF ROAD LINER 2663
MAINTENANCE STANDARD OF FLAT SHOE .2664
HYDRAULIC SYSTEM 2665
MAINTENANCE STANDARD OF HYDRAULIC TANK 2665
MAINTENANCE STANDARD OF MAIN PUMP .2666
MAINTENANCE STANDARD OF LS-EPC VALVE 2667
MAINTENANCE STANDARD OF PC-EPC VALVE 2668
MAINTENANCE STANDARD OF SWING MOTOR .2669
MAINTENANCE STANDARD OF TRAVEL MOTOR 2672
MAINTENANCE STANDARD OF CONTROL VALVE .2675
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2685
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2687
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2689
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2692
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2695
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2697
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2698
MAINTENANCE STANDARD OF SOLENOID VALVE 2700
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2701
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2702
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2703
WORK EQUIPMENT 2704
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2704
DIMENSION OF ARM 2709
DIMENSIONS OF BUCKET 2711
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2713
MAINTENANCE STANDARD OF ARM CYLINDER 2714
MAINTENANCE STANDARD OF BUCKET CYLINDER .2715
80 APPENDIX .2717
CONTENTS 2718
ABBREVIATION LIST .2720
AIR CONDITIONER SYSTEM 2726
PRECAUTIONS FOR REFRIGERANT .2726
AIR CONDITIONER COMPONENT .2727
SPECIFICATIONS OF AIR CONDITIONER .2729
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2730
OUTLINE OF REFRIGERATION CYCLE 2731
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2733
AIR CONDITIONER UNIT 2733
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2733
FUNCTION OF AIR CONDITIONER UNIT 2735
COMPONENT PARTS OF AIR CONDITIONER UNIT .2736
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2736
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2736
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2736
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2736
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2737
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2737
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2737
FUNCTION OF DUAL PRESSURE SWITCH 2738
AIR CONDITIONER CONTROLLER 2739
STRUCTURE OF AIR CONDITIONER CONTROLLER .2739
COMPRESSOR 2740
STRUCTURE OF COMPRESSOR .2740
SPECIFICATIONS OF COMPRESSOR 2740
FUNCTION OF COMPRESSOR 2740
CONDENSER .2741
STRUCTURE OF CONDENSER 2741
SPECIFICATIONS OF CONDENSER .2741
FUNCTION OF CONDENSER .2741
SENSORS FOR AIR CONDITIONER SYSTEM 2743
STRUCTURE OF SUNLIGHT SENSOR 2743
FUNCTION OF SUNLIGHT SENSOR .2743
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2743
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2743
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2745
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2747
AIR CONDITIONER SYSTEM DIAGRAM 2749
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2750
FUNCTION OF AIR CONDITIONER CONTROLLER 2751
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2752
TESTING AIR LEAKAGE (DUCT) 2761
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2761
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2763
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2764
TEST VENT (MODE) CHANGEOVER .2765
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2765
TESTING FRESH/RECIRC AIR CHANGEOVER .2766
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2766
TEST SUNLIGHT SENSOR 2767
METHOD FOR TESTING SUNLIGHT SENSOR 2767
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2768
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2768
TEST RELAYS .2770
METHOD FOR TESTING RELAYS .2770
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2771
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2772
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2775
FAILURE CODE [879AKA] .2777
FAILURE CODE [879AKB] .2778
FAILURE CODE [879BKA] .2779
FAILURE CODE [879BKB] .2781
FAILURE CODE [879CKA] .2783
FAILURE CODE [879CKB] .2784
FAILURE CODE [879DKZ] .2785
FAILURE CODE [879EMC] .2787
FAILURE CODE [879FMC] .2788
FAILURE CODE [879GKX] .2789
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2791
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2793
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2796
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2798
TROUBLESHOOTING USING GAUGE PRESSURE 2800
CONNECTION OF SERVICE TOOL 2802
METHOD FOR CONNECTING SERVICE TOOL 2802
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2804
HANDLE COMPRESSOR OIL .2806
METHOD FOR REPLACING DESICCANT 2808
90 CIRCUIT DIAGRAMS .2811
CONTENTS 2812
ABBREVIATION LIST .2813
HYDRAULIC CIRCUIT DIAGRAM .2819
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2819
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2823
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2825
ELECTRICAL CIRCUIT DIAGRAM 2827
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2827
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2831
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/8) 2833
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/8) 2835
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/8) 2837
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/8) 2839
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/8) 2841
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2843
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2845
INDEX 2847

DESCRIPTION:

Komatsu PC228USLC-11 Hydraulic Excavator Shop Manual EENBM00103  – 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