Komatsu PC228USLC-11E0 Hydraulic Excavator Shop Manual UENBM00552 PDF

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Komatsu PC228USLC-11E0 Hydraulic Excavator Shop Manual UENBM00552 – PDF DOWNLOAD

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Komatsu PC228USLC-11E0 Hydraulic Excavator Shop Manual UENBM00552 – PDF DOWNLOAD

Language : English
Pages : 3134
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC228USLC-11E0 Hydraulic Excavator Shop Manual UENBM00552 – PDF DOWNLOAD

• SERIAL NUMBERS 6826 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 23
FOREWORD, SAFETY, BASIC INFORMATION . 29
HOW TO READ THE SHOP MANUAL . 29
SAFETY NOTICE FOR OPERATION . 31
PRECAUTIONS TO PREVENT FIRE . 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 43
PRECAUTIONS FOR DEF . 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING . 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 44
THE OTHER PRECAUTIONS . 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS . 95
CONTENTS 96
SPECIFICATIONS 97
SPECIFICATION DRAWING . 97
SPECIFICATION DRAWING: PC228USLC-11E0 . 97
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC228USLC-11 . 99
SPECIFICATIONS 100
SPECIFICATIONS: PC228USLC-11E0 100
WEIGHT TABLE 103
WEIGHT TABLE: PC228USLC-11 103
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 105
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE . 105
10 STRUCTURE AND FUNCTION . 107
CONTENTS 108
UREA SCR SYSTEM . 112
LAYOUT DRAWING OF UREA SCR SYSTEM . 112
UREA SCR SYSTEM DIAGRAM . 117
FUNCTION OF UREA SCR SYSTEM . 118
FUNCTION OF AdBlue/DEF SYSTEM . 118
INDUCEMENT STRATEGY . 120
COMPONENT PARTS OF UREA SCR SYSTEM 128
AdBlue/DEF MIXING TUBE 128
SCR ASSEMBLY 128
AdBlue/DEF TANK . 131
AdBlue/DEF PUMP . 133
AdBlue/DEF INJECTOR . 134
AdBlue/DEF HOSE . 135
AdBlue/DEF TANK HEATING VALVE . 136
BOOT-UP SYSTEM 137
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 137
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 139
SYSTEM OPERATING LAMP SYSTEM 141
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 141
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 141
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 142
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 142
BATTERY DISCONNECT SWITCH . 144
FUNCTION OF BATTERY DISCONNECT SWITCH . 144
ENGINE SYSTEM . 145
LAYOUT DRAWING OF ENGINE SYSTEM . 145
SPECIFICATIONS OF ENGINE SYSTEM . 146
FUNCTION OF ENGINE SYSTEM . 146
ENGINE CONTROL SYSTEM . 147
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 147
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 148
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 150
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 151
AUTO-DECELERATION SYSTEM 153
AUTO-DECELERATION SYSTEM DIAGRAM 153
FUNCTION OF AUTO-DECELERATION SYSTEM 153
OPERATION OF AUTO-DECELERATION SYSTEM . 154
ENGINE AUTOMATIC WARM-UP SYSTEM . 155
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 155
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 156
OVERHEAT PREVENTION SYSTEM 157
OVERHEAT PREVENTION SYSTEM DIAGRAM 157
FUNCTION OF OVERHEAT PREVENTION SYSTEM 158
TURBOCHARGER PROTECTION SYSTEM 160
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 160
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 161
AUTOMATIC IDLE STOP SYSTEM 162
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 162
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 163
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 163
COMPONENT PARTS OF ENGINE SYSTEM 166
VGT . 166
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 (MACHINE WITH KOMTRAX TERMINAL) 191
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 194
MACHINE MONITOR SYSTEM 197
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 197
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 198
FUNCTION OF MACHINE MONITOR SYSTEM 198
KomVision SYSTEM 200
LAYOUT DRAWING OF KomVision SYSTEM 200
KomVision SYSTEM DIAGRAM 202
FUNCTION OF KomVision SYSTEM 202
KOMTRAX SYSTEM 204
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 204
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 204
FUNCTION OF KOMTRAX SYSTEM 205
COMPONENT PARTS OF CONTROL SYSTEM . 206
MACHINE MONITOR . 206
KomVision CONTROLLER 220
KomVision CAMERA 224
KOMTRAX TERMINAL 224
GATEWAY FUNCTION CONTROLLER . 226
COMMUNICATION TERMINAL 229
PUMP CONTROLLER . 231
RESISTOR FOR PC-EPC VALVE . 235
CAN TERMINATING RESISTOR 235
ENGINE CONTROLLER . 237
FUEL CONTROL DIAL . 243
HYDRAULIC SYSTEM 245
LAYOUT DRAWING OF HYDRAULIC SYSTEM 245
CLSS 249
STRUCTURE OF CLSS . 249
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 251
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 252
PRESSURE COMPENSATION CONTROL . 265
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 268
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 268
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 269
PUMP AND VALVE CONTROL SYSTEM . 274
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 274
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 275
COMPONENT PARTS OF HYDRAULIC SYSTEM . 277
HYDRAULIC TANK 277
MAIN PUMP . 279
CONTROL VALVE . 304
WORK EQUIPMENT SYSTEM . 362
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 362
ONE-TOUCH POWER MAXIMIZING SYSTEM . 367
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 367
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 368
PPC LOCK SYSTEM . 369
PPC LOCK SYSTEM DIAGRAM . 369
FUNCTION OF PPC LOCK SYSTEM . 369
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 370
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 370
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 370
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 371
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 372
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 372
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 373
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 374
WORK EQUIPMENT AND SWING PPC VALVE 374
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 379
2ND-LINE ATTACHMENT PPC VALVE . 384
SOLENOID VALVE 386
ANTI-DROP VALVE FOR BOOM 390
ANTI-DROP VALVE FOR ARM . 394
BOOM ANGLE POTENTIOMETER 398
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 399
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 401
PILOT CIRCUIT ACCUMULATOR . 403
ATTACHMENT CIRCUIT ACCUMULATOR 404
SWING SYSTEM 405
LAYOUT DRAWING OF SWING SYSTEM 405
SWING CONTROL SYSTEM DIAGRAM 409
FUNCTION OF SWING CONTROL SYSTEM 409
COMPONENT PARTS OF SWING SYSTEM . 413
SWING MOTOR . 413
SWING MACHINERY . 424
SWING CIRCLE 425
TRAVEL SYSTEM . 427
LAYOUT DRAWING OF TRAVEL SYSTEM . 427
TRAVEL CONTROL SYSTEM DIAGRAM . 431
FUNCTION OF TRAVEL CONTROL SYSTEM . 431
COMPONENT PARTS OF TRAVEL SYSTEM 433
TRAVEL MOTOR 433
FINAL DRIVE . 445
TRAVEL PPC VALVE 447
CENTER SWIVEL JOINT . 452
UNDERCARRIAGE AND FRAME . 454
LAYOUT DRAWING OF UNDERCARRIAGE . 454
SPECIFICATIONS OF UNDERCARRIAGE . 455
WORK EQUIPMENT 456
STRUCTURE OF WORK EQUIPMENT . 456
FUNCTION OF WORK EQUIPMENT 457
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 458
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 458
BUCKET CLEARANCE ADJUSTMENT SHIM 459
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 459
CAB AND ITS ATTACHMENTS . 460
ROPS CAB 460
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) . 460
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 461
FUNCTION OF ROPS CAB 461
CAB MOUNT . 462
STRUCTURE OF CAB MOUNT 462
FUNCTION OF CAB MOUNT . 462
CAB TIPPING STOPPER . 463
STRUCTURE OF CAB TIPPING STOPPER 463
FUNCTION OF CAB TIPPING STOPPER . 463
TAKE WIRING HARNESS OUT OF CAB 464
20 STANDARD VALUE TABLE . 465
CONTENTS 466
STANDARD VALUE TABLE FOR ENGINE . 467
STANDARD VALUE TABLE FOR ENGINE: PC228USLC-11E0 . 467
STANDARD VALUE TABLE FOR MACHINE 472
STANDARD VALUE TABLE FOR MACHINE: PC228USLC-11E0 472
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 486
30 TESTING AND ADJUSTING 491
CONTENTS 492
RELATED INFORMATION ON TESTING AND ADJUSTING 496
TOOLS FOR TESTING AND ADJUSTING . 496
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 503
ENGINE AND COOLING SYSTEM . 505
TEST ENGINE SPEED . 505
METHOD FOR TESTING ENGINE SPEED . 505
TEST BOOST PRESSURE . 508
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 508
METHOD FOR TESTING BOOST PRESSURE . 509
TEST EXHAUST GAS COLOR 511
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 511
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 512
TEST AND ADJUST VALVE CLEARANCE . 514
METHOD FOR TESTING VALVE CLEARANCE 514
METHOD FOR ADJUSTING VALVE CLEARANCE 515
TEST COMPRESSION PRESSURE . 517
METHOD FOR TESTING COMPRESSION PRESSURE . 517
TEST BLOWBY PRESSURE 522
METHOD FOR TESTING BLOWBY PRESSURE 522
TEST ENGINE OIL PRESSURE 524
METHOD FOR TESTING ENGINE OIL PRESSURE 524
TEST EGR VALVE AND VGT OIL PRESSURE . 525
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 525
TEST FUEL PRESSURE 527
METHOD FOR TESTING FUEL PRESSURE 528
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 533
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 534
BLEEDING AIR FROM FUEL SYSTEM . 540
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 540
TEST FUEL CIRCUIT FOR LEAKAGE . 541
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 541
HANDLE CYLINDER CUT-OUT MODE OPERATION 543
HANDLE NO-INJECTION CRANKING OPERATION 544
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 545
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 545
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 545
TEST COOLING FAN SPEED 547
METHOD FOR TESTING COOLING FAN SPEED 547
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 548
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 548
TEST SCR RELATED FUNCTIONS 549
TEST AdBlue/DEF PUMP RAISED PRESSURE 552
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 555
TEST AdBlue/DEF LINE HEATER RELAY 1 . 559
TEST AdBlue/DEF LINE HEATER RELAY 2 . 562
TEST AdBlue/DEF PUMP HEATER RELAY . 564
TEST AdBlue/DEF TANK HEATER VALVE . 568
TEST DENITRATION EFFICIENCY OF SCR 570
CLEAN AdBlue/DEF TANK . 575
METHOD FOR CLEANING AdBlue/DEF TANK . 575
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 579
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 579
POWER TRAIN . 581
TEST SWING CIRCLE BEARING CLEARANCE . 581
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 581
UNDERCARRIAGE AND FRAME . 582
TEST AND ADJUST TRACK TENSION . 582
METHOD FOR TESTING TRACK TENSION 582
METHOD FOR ADJUSTING TRACK TENSION 582
HYDRAULIC SYSTEM 584
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 584
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 584
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 584
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 589
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 589
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 590
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 591
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 599
TEST OIL PRESSURE OF CONTROL CIRCUIT 601
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 601
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 603
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 603
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE . 604
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 605
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 607
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 607
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 609
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 610
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 611
METHOD FOR ADJUSTING LS VALVE . 612
TEST OUTLET PRESSURE OF SOLENOID VALVE 613
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 613
OPERATING CONDITION OF SOLENOID VALVE . 614
TEST PPC VALVE OUTLET PRESSURE 617
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 617
TEST ATTACHMENT CIRCUIT OIL PRESSURE 620
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 620
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 621
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 621
TEST PUMP SWASH PLATE SENSOR 622
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 622
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 623
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 623
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 624
METHOD FOR TESTING OF THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM LOCK VALVE 624
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 624
TEST OIL LEAKAGE 626
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 626
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 626
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 627
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 627
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 628
BLEED AIR FROM HYDRAULIC CIRCUIT 629
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 631
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 633
TEST ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) . 633
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) . 637
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 637
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 641
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 641
WORK EQUIPMENT 648
ADJUST BOOM ANGLE POTENTIOMETER . 648
METHOD FOR ADJUSTING BOOM ANGLE POTENTIOMETER . 648
CAB AND ITS ATTACHMENTS . 649
TEST CAB TIPPING STOPPER 649
METHOD FOR TESTING CAB TIPPING STOPPER 649
METHOD FOR ADJUSTING MIRRORS 650
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 650
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 651
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 652
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 653
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (C) 654
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (C) 654
PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (D) . 656
ELECTRICAL SYSTEM . 657
SET AND OPERATE MACHINE MONITOR . 657
OPERATOR MODE . 661
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 661
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 661
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 662
CHECKING FUNCTION OF SERVICE METER 662
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 662
SERVICE MODE 665
METHOD FOR OPERATING SERVICE MODE . 665
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 668
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 675
ABNORMALITY RECORD MENU . 685
METHOD FOR CONFIRMING MAINTENANCE RECORD 690
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 691
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 695
DEFAULT MENU 696
DIAGNOSTIC TESTS MENU . 708
ADJUSTMENT MENU . 717
METHOD FOR PERFORMING NO-INJECTION CRANKING . 751
KOMTRAX SETTINGS MENU . 752
METHOD FOR DISPLAYING SERVICE MESSAGE . 754
METHOD FOR STARTING UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) . 756
METHOD FOR STARTING UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 761
ADJUST REARVIEW CAMERA ANGLE 766
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 766
ADJUST KomVision CAMERA ANGLE . 768
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 769
ADJUST KomVision RELATED ITEMS 771
SETTING OF KomVision (MAIN SETTING) . 771
SETTING OF KomVision (CAMERA SETTING) . 773
SETTING OF KomVision (CAMERA CALIBRATION) . 775
KomVision screen – Check 12 m visibility 788
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 791
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 792
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 793
TEST DIODES . 794
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 794
METHOD FOR TESTING DIODE USING ANALOG TESTER 794
Pm CLINIC . 795
Pm CLINIC SERVICE . 795
Pm CLINIC CHECK SHEET: PC228USLC-11E0 . 796
40 TROUBLESHOOTING 807
CONTENTS 808
ABBREVIATION LIST . 820
RELATED INFORMATION ON TROUBLESHOOTING 826
GENERAL TROUBLESHOOTING POINTS 826
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 827
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 839
CHECKS BEFORE TROUBLESHOOTING . 841
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 843
WALK-AROUND CHECK . 843
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 845
CHECK FUEL LEVEL AND TYPE . 845
CHECK IMPURE INGREDIENT IN FUEL . 845
CHECK FUEL PREFILTER 846
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 846
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 847
CHECK MAIN FILTER . 848
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 850
CHECK COOLANT LEVEL (RESERVOIR TANK) 851
CHECK CLOGGING OF AIR CLEANER . 851
OUTER ELEMENT – CLEAN . 852
ELEMENTS – REPLACE 854
CHECK HYDRAULIC OIL LEVEL . 855
CHECK HYDRAULIC OIL STRAINER 856
CHECK HYDRAULIC FILTER 857
CHECK OIL LEVEL IN SWING MACHINERY CASE . 858
CHECK OIL LEVEL IN DAMPER CASE 859
CHECK OIL LEVEL IN FINAL DRIVE CASE . 859
BLEED AIR FROM FUEL SYSTEM 860
BLEED AIR FROM HYDRAULIC SYSTEM . 860
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 860
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 866
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 866
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 866
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 867
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 868
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 868
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 869
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 873
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 876
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 880
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 882
CONNECTOR LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) . 885
CONNECTOR LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 899
CONNECTOR CONTACT IDENTIFICATION 913
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 953
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) . 959
FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 962
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 965
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 969
FAILURE CODE TABLE 971
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 991
FAILURE CODE [879AKA] . 991
FAILURE CODE [879AKB] . 992
FAILURE CODE [879BKA] . 993
FAILURE CODE [879BKB] . 995
FAILURE CODE [879CKA] . 997
FAILURE CODE [879CKB] . 998
FAILURE CODE [879DKZ] . 999
FAILURE CODE [879EMC] .1001
FAILURE CODE [879FMC] .1002
FAILURE CODE [879GKX] .1003
FAILURE CODE [989L00] .1005
FAILURE CODE [989M00] .1006
FAILURE CODE [989N00] .1007
FAILURE CODE [A000N1] .1008
FAILURE CODE [A1U0N3] .1009
FAILURE CODE [A1U0N4] .1011
FAILURE CODE [A900FR] .1013
FAILURE CODE [A900N6] .1014
FAILURE CODE [A900NY] .1015
FAILURE CODE [AA10NX] .1016
FAILURE CODE [AB00KE] .1018
FAILURE CODE [AQ10N3] .1020
FAILURE CODE [AS00N3] .1022
FAILURE CODE [AS00R2] .1024
FAILURE CODE [AS00R3] .1025
FAILURE CODE [AS00R4] .1026
FAILURE CODE [AS00R5] .1027
FAILURE CODE [AS00R6] .1028
FAILURE CODE [AS00ZK] .1029
FAILURE CODE [AS10KM] .1030
FAILURE CODE [AS10NR] .1031
FAILURE CODE [AS10NT] .1032
FAILURE CODE [B@BAZG] .1033
FAILURE CODE [B@BAZK] .1035
FAILURE CODE [B@BCNS] .1037
FAILURE CODE [B@BCQA] .1039
FAILURE CODE [B@BCZK] .1041
FAILURE CODE [B@HANS] .1043
FAILURE CODE [CA115] 1045
FAILURE CODE [CA122] 1050
FAILURE CODE [CA123] 1053
FAILURE CODE [CA131] 1055
FAILURE CODE [CA132] 1057
FAILURE CODE [CA144] 1059
FAILURE CODE [CA145] 1061
FAILURE CODE [CA153] 1063
FAILURE CODE [CA154] 1065
FAILURE CODE [CA187] 1067
FAILURE CODE [CA221] 1069
FAILURE CODE [CA222] 1071
FAILURE CODE [CA227] 1073
FAILURE CODE [CA234] 1074
FAILURE CODE [CA238] 1075
FAILURE CODE [CA239] 1076
FAILURE CODE [CA249] 1077
FAILURE CODE [CA256] 1079
FAILURE CODE [CA271] 1081
FAILURE CODE [CA272] 1083
FAILURE CODE [CA322] 1085
FAILURE CODE [CA323] 1087
FAILURE CODE [CA324] 1089
FAILURE CODE [CA325] 1091
FAILURE CODE [CA331] 1093
FAILURE CODE [CA332] 1095
FAILURE CODE [CA343] 1097
FAILURE CODE [CA351] 1099
FAILURE CODE [CA352] 1101
FAILURE CODE [CA356] 1103
FAILURE CODE [CA357] 1105
FAILURE CODE [CA386] 1107
FAILURE CODE [CA428] 1109
FAILURE CODE [CA429] 1111
FAILURE CODE [CA435] 1113
FAILURE CODE [CA441] 1115
FAILURE CODE [CA442] 1117
FAILURE CODE [CA449] 1118
FAILURE CODE [CA451] 1119
FAILURE CODE [CA452] 1121
FAILURE CODE [CA488] 1123
FAILURE CODE [CA515] 1126
FAILURE CODE [CA516] 1128
FAILURE CODE [CA553] 1130
FAILURE CODE [CA555] 1131
FAILURE CODE [CA556] 1133
FAILURE CODE [CA559] 1135
FAILURE CODE [CA595] 1138
FAILURE CODE [CA687] 1140
FAILURE CODE [CA689] 1142
FAILURE CODE [CA691] 1145
FAILURE CODE [CA692] 1147
FAILURE CODE [CA697] 1149
FAILURE CODE [CA698] 1150
FAILURE CODE [CA731] 1151
FAILURE CODE [CA778] 1153
FAILURE CODE [CA1117] .1158
FAILURE CODE [CA1664] .1159
FAILURE CODE [CA1669] .1162
FAILURE CODE [CA1673] .1163
FAILURE CODE [CA1677] .1164
FAILURE CODE [CA1678] .1165
FAILURE CODE [CA1682] .1166
FAILURE CODE [CA1683] .1170
FAILURE CODE [CA1684] .1172
FAILURE CODE [CA1686] .1174
FAILURE CODE [CA1691] .1175
FAILURE CODE [CA1694] .1178
FAILURE CODE [CA1695] .1181
FAILURE CODE [CA1696] .1183
FAILURE CODE [CA1712] .1185
FAILURE CODE [CA1713] .1188
FAILURE CODE [CA1714] .1191
FAILURE CODE [CA1715] .1192
FAILURE CODE [CA1776] .1193
FAILURE CODE [CA1777] .1196
FAILURE CODE [CA1843] .1199
FAILURE CODE [CA1844] .1201
FAILURE CODE [CA1879] .1203
FAILURE CODE [CA1881] .1205
FAILURE CODE [CA1883] .1207
FAILURE CODE [CA1885] .1211
FAILURE CODE [CA1887] .1213
FAILURE CODE [CA1921] .1215
FAILURE CODE [CA1922] .1218
FAILURE CODE [CA1942] .1223
FAILURE CODE [CA1993] .1225
FAILURE CODE [CA2185] .1227
FAILURE CODE [CA2186] .1228
FAILURE CODE [CA2249] .1230
FAILURE CODE [CA2271] .1233
FAILURE CODE [CA2272] .1235
FAILURE CODE [CA2288] .1237
FAILURE CODE [CA2311] .1239
FAILURE CODE [CA2349] .1241
FAILURE CODE [CA2353] .1243
FAILURE CODE [CA2357] .1245
FAILURE CODE [CA2381] .1248
FAILURE CODE [CA2382] .1250
FAILURE CODE [CA2383] .1253
FAILURE CODE [CA2386] .1255
FAILURE CODE [CA2387] .1257
FAILURE CODE [CA2555] .1260
FAILURE CODE [CA2556] .1262
FAILURE CODE [CA2637] .1264
FAILURE CODE [CA2639] .1266
FAILURE CODE [CA2771] .1268
FAILURE CODE [CA2777] .1273
FAILURE CODE [CA2976] .1276
FAILURE CODE [CA3133] .1278
FAILURE CODE [CA3134] .1280
FAILURE CODE [CA3135] .1282
FAILURE CODE [CA3142] .1285
FAILURE CODE [CA3143] .1286
FAILURE CODE [CA3144] .1287
FAILURE CODE [CA3146] .1290
FAILURE CODE [CA3147] .1291
FAILURE CODE [CA3148] .1292
FAILURE CODE [CA3151] .1295
FAILURE CODE [CA3165] .1301
FAILURE CODE [CA3228] .1304
FAILURE CODE [CA3229] .1307
FAILURE CODE [CA3231] .1310
FAILURE CODE [CA3232] .1313
FAILURE CODE [CA3235] .1318
FAILURE CODE [CA3239] .1321
FAILURE CODE [CA3241] .1324
FAILURE CODE [CA3242] .1326
FAILURE CODE [CA3251] .1329
FAILURE CODE [CA3253] .1331
FAILURE CODE [CA3254] .1335
FAILURE CODE [CA3255] .1339
FAILURE CODE [CA3256] .1342
FAILURE CODE [CA3311] .1345
FAILURE CODE [CA3312] .1348
FAILURE CODE [CA3313] .1351
FAILURE CODE [CA3314] .1352
FAILURE CODE [CA3315] .1353
FAILURE CODE [CA3316] .1355
FAILURE CODE [CA3317] .1356
FAILURE CODE [CA3318] .1357
FAILURE CODE [CA3319] .1360
FAILURE CODE [CA3321] .1362
FAILURE CODE [CA3322] .1364
FAILURE CODE [CA3419] .1366
FAILURE CODE [CA3421] .1368
FAILURE CODE [CA3497] .1370
FAILURE CODE [CA3498] .1371
FAILURE CODE [CA3543] .1372
FAILURE CODE [CA3545] .1378
FAILURE CODE [CA3547] .1380
FAILURE CODE [CA3558] .1381
FAILURE CODE [CA3559] .1383
FAILURE CODE [CA3562] .1385
FAILURE CODE [CA3563] .1387
FAILURE CODE [CA3567] .1390
FAILURE CODE [CA3568] .1393
FAILURE CODE [CA3571] .1398
FAILURE CODE [CA3572] .1400
FAILURE CODE [CA3574] .1402
FAILURE CODE [CA3575] .1405
FAILURE CODE [CA3577] .1407
FAILURE CODE [CA3578] .1409
FAILURE CODE [CA3582] .1411
FAILURE CODE [CA3583] .1419
FAILURE CODE [CA3596] .1421
FAILURE CODE [CA3649] .1426
FAILURE CODE [CA3681] .1429
FAILURE CODE [CA3682] .1434
FAILURE CODE [CA3713] .1439
FAILURE CODE [CA3717] .1442
FAILURE CODE [CA3718] .1443
FAILURE CODE [CA3725] .1444
FAILURE CODE [CA3741] .1447
FAILURE CODE [CA3748] .1448
FAILURE CODE [CA3751] .1450
FAILURE CODE [CA3755] .1452
FAILURE CODE [CA3866] .1454
FAILURE CODE [CA3867] .1458
FAILURE CODE [CA3868] .1461
FAILURE CODE [CA3899] .1466
FAILURE CODE [CA3911] .1468
FAILURE CODE [CA3912] .1473
FAILURE CODE [CA3932] .1475
FAILURE CODE [CA3933] .1477
FAILURE CODE [CA3934] .1479
FAILURE CODE [CA3935] .1482
FAILURE CODE [CA3936] .1484
FAILURE CODE [CA4151] .1486
FAILURE CODE [CA4152] .1492
FAILURE CODE [CA4155] .1497
FAILURE CODE [CA4156] .1499
FAILURE CODE [CA4157] .1502
FAILURE CODE [CA4158] .1504
FAILURE CODE [CA4159] .1505
FAILURE CODE [CA4161] .1506
FAILURE CODE [CA4162] .1509
FAILURE CODE [CA4163] .1512
FAILURE CODE [CA4164] .1513
FAILURE CODE [CA4165] .1515
FAILURE CODE [CA4166] .1517
FAILURE CODE [CA4168] .1519
FAILURE CODE [CA4169] .1523
FAILURE CODE [CA4171] .1527
FAILURE CODE [CA4249] .1531
FAILURE CODE [CA4251] .1535
FAILURE CODE [CA4259] .1539
FAILURE CODE [CA4261] .1542
FAILURE CODE [CA4277] .1545
FAILURE CODE [CA4281] .1548
FAILURE CODE [CA4459] .1551
FAILURE CODE [CA4461] .1553
FAILURE CODE [CA4658] .1556
FAILURE CODE [CA4731] .1559
FAILURE CODE [CA4732] .1560
FAILURE CODE [CA4739] .1561
FAILURE CODE [CA4768] .1562
FAILURE CODE [CA4769] .1564
FAILURE CODE [CA4842] .1567
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) .1570
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1572
FAILURE CODE [CA5115] .1574
FAILURE CODE [CA5179] .1577
FAILURE CODE [CA5181] .1579
FAILURE CODE [CA5383] .1581
FAILURE CODE [D110KB] .1583
FAILURE CODE [D197KA] .1585
FAILURE CODE [D197KB] .1587
FAILURE CODE [D197KY] .1589
FAILURE CODE [D19JKZ] .1591
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) .1594
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1595
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) .1596
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1598
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) .1600
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1603
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) .1606
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1608
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) .1610
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1617
FAILURE CODE [D8ARKR] .1624
FAILURE CODE [D8G1KT] .1629
FAILURE CODE [D8G6KT] .1630
FAILURE CODE [DA20MC] .1631
FAILURE CODE [DA22KK] .1632
FAILURE CODE [DA25KP] .1635
FAILURE CODE [DA26KP] .1638
FAILURE CODE [DA29KQ] .1640
FAILURE CODE [DA2LKA] (MACHINE WITH KOMTRAX TERMINAL) .1643
FAILURE CODE [DA2LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1646
FAILURE CODE [DA2LKB] (MACHINE WITH KOMTRAX TERMINAL) .1649
FAILURE CODE [DA2LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1651
FAILURE CODE [DA2QKR] (MACHINE WITH KOMTRAX TERMINAL) .1653
FAILURE CODE [DA2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1662
FAILURE CODE [DA2RKR] .1671
FAILURE CODE [DAF0KM] .1676
FAILURE CODE [DAF0MB] .1677
FAILURE CODE [DAF0MC] .1678
FAILURE CODE [DAF8KB] .1679
FAILURE CODE [DAF9KQ] .1681
FAILURE CODE [DAFGMC] .1682
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) .1683
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1686
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) .1689
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1691
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) .1693
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1701
FAILURE CODE [DAZ9KQ] .1709
FAILURE CODE [DAZQKR] (MACHINE WITH KOMTRAX TERMINAL) .1710
FAILURE CODE [DAZQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1717
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) .1724
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1732
FAILURE CODE [DB2RKR] .1740
FAILURE CODE [DBP0KM] .1746
FAILURE CODE [DBP0KT] .1747
FAILURE CODE [DBP5KB] .1748
FAILURE CODE [DBP5KY] .1750
FAILURE CODE [DBPQKR] (MACHINE WITH KOMTRAX TERMINAL) .1752
FAILURE CODE [DBPQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1760
FAILURE CODE [DDNRKA] .1768
FAILURE CODE [DDNRKY] .1770
FAILURE CODE [DDNS00] .1772
FAILURE CODE [DFB1KZ] .1774
FAILURE CODE [DFB2KZ] .1776
FAILURE CODE [DFB3L8] .1778
FAILURE CODE [DFB4L8] .1780
FAILURE CODE [DFB5KZ] .1782
FAILURE CODE [DFB6KZ] .1784
FAILURE CODE [DGH2KA] .1786
FAILURE CODE [DGH2KB] .1788
FAILURE CODE [DHA4KA] .1790
FAILURE CODE [DHAAMA] .1792
FAILURE CODE [DHACMA] .1794
FAILURE CODE [DHPAMA] .1796
FAILURE CODE [DHPBMA] .1798
FAILURE CODE [DHPCKX] .1800
FAILURE CODE [DHPDKX] .1802
FAILURE CODE [DHX1MA] .1804
FAILURE CODE [DHS3MA] .1805
FAILURE CODE [DHS4MA] .1807
FAILURE CODE [DHS8MA] .1809
FAILURE CODE [DHS9MA] .1811
FAILURE CODE [DHSAMA] .1813
FAILURE CODE [DHSBMA] .1815
FAILURE CODE [DHSCMA] .1817
FAILURE CODE [DHSDMA] .1819
FAILURE CODE [DHSFMA] .1821
FAILURE CODE [DHSGMA] .1823
FAILURE CODE [DHSHMA] .1825
FAILURE CODE [DHSJMA] .1827
FAILURE CODE [DHZAMA] .1829
FAILURE CODE [DHZCL8] .1833
FAILURE CODE [DKR0MA] .1834
FAILURE CODE [DKR1MA] .1837
FAILURE CODE [DKA0KA] .1840
FAILURE CODE [DKA0KB] .1842
FAILURE CODE [DKA0PH] .1844
FAILURE CODE [DKC0KA] .1845
FAILURE CODE [DKC0KB] .1848
FAILURE CODE [DKC0PH] .1851
FAILURE CODE [DKULKA] .1852
FAILURE CODE [DKULKB] .1854
FAILURE CODE [DKULKY] .1856
FAILURE CODE [DLM5KA] .1858
FAILURE CODE [DLM5MB] .1860
FAILURE CODE [DR10KA] .1863
FAILURE CODE [DR12KA] .1865
FAILURE CODE [DR20KA] .1867
FAILURE CODE [DR21KX] .1869
FAILURE CODE [DR31KX] .1871
FAILURE CODE [DR40KA] .1873
FAILURE CODE [DUMBKA] (MACHINE WITH KOMTRAX TERMINAL) .1875
FAILURE CODE [DUMBKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1878
FAILURE CODE [DUMBKB] (MACHINE WITH KOMTRAX TERMINAL) .1881
FAILURE CODE [DUMBKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1883
FAILURE CODE [DV00KA] .1885
FAILURE CODE [DV00KB] .1886
FAILURE CODE [DV20KB] .1887
FAILURE CODE [DW43KA] .1889
FAILURE CODE [DW43KB] .1891
FAILURE CODE [DW43KY] .1893
FAILURE CODE [DW45KA] .1895
FAILURE CODE [DW45KB] .1898
FAILURE CODE [DW45KY] .1901
FAILURE CODE [DW4CKY] .1903
FAILURE CODE [DW4GKA] .1905
FAILURE CODE [DW4GKB] .1907
FAILURE CODE [DW4WKA] .1909
FAILURE CODE [DW4WKB] .1911
FAILURE CODE [DW4WKY] .1913
FAILURE CODE [DW91KA] .1915
FAILURE CODE [DW91KB] .1917
FAILURE CODE [DW91KY] .1919
FAILURE CODE [DWA2KA] .1921
FAILURE CODE [DWA2KB] .1923
FAILURE CODE [DWA2KY] .1925
FAILURE CODE [DWK0KA] .1927
FAILURE CODE [DWK0KB] .1929
FAILURE CODE [DWK0KY] .1931
FAILURE CODE [DWK2KA] .1933
FAILURE CODE [DWK2KB] .1935
FAILURE CODE [DWK2KY] .1937
FAILURE CODE [DWK8KA] .1939
FAILURE CODE [DWK8KB] .1941
FAILURE CODE [DWK8KY] .1943
FAILURE CODE [DWN5KA] .1945
FAILURE CODE [DWN5KB] .1947
FAILURE CODE [DWN5KY] .1949
FAILURE CODE [DWPUKA] .1951
FAILURE CODE [DWPUKB] .1953
FAILURE CODE [DWPUKY] .1955
FAILURE CODE [DXA8KA] .1957
FAILURE CODE [DXA8KB] .1959
FAILURE CODE [DXA9KA] .1961
FAILURE CODE [DXA9KB] .1963
FAILURE CODE [DXE0KA] .1965
FAILURE CODE [DXE0KB] .1967
FAILURE CODE [DXE4KA] .1969
FAILURE CODE [DXE4KB] .1971
FAILURE CODE [DXE4KY] .1973
FAILURE CODE [DXE5KA] .1975
FAILURE CODE [DXE5KB] .1977
FAILURE CODE [DXE6KA] .1979
FAILURE CODE [DXE6KB] .1981
FAILURE CODE [DXE7KA] .1983
FAILURE CODE [DXE7KB] .1985
FAILURE CODE [DXE7KY] .1987
FAILURE CODE [DXE8KA] .1989
FAILURE CODE [DXE8KB] .1991
FAILURE CODE [DXE8KY] .1993
FAILURE CODE [DXE9KA] .1995
FAILURE CODE [DXE9KB] .1997
FAILURE CODE [DXE9KY] .1999
FAILURE CODE [DXEAKA] .2001
FAILURE CODE [DXEAKB] .2003
FAILURE CODE [DXEAKY] .2005
FAILURE CODE [DXEKKA] .2007
FAILURE CODE [DXEKKB] .2009
FAILURE CODE [DXEKKY] .2011
FAILURE CODE [DXELKA] .2013
FAILURE CODE [DXELKB] .2015
FAILURE CODE [DXELKY] .2017
FAILURE CODE [DY20KA] .2019
FAILURE CODE [DY20MA] .2021
FAILURE CODE [DY2CKB] .2023
FAILURE CODE [DY2DKB] .2025
FAILURE CODE [DY2EKB] .2027
FAILURE CODE [F313KA] .2029
FAILURE CODE [F313KB] .2031
FAILURE CODE [F318KB] .2034
FAILURE CODE [F318KY] .2037
FAILURE CODE [F7FQKR] .2039
FAILURE CODE [F7G0MC] .2041
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2042
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2042
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2048
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2051
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2053
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2055
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2058
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2059
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .2060
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2061
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .2062
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2063
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2064
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2065
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2066
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2067
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2068
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2069
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .2071
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2072
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2073
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2074
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .2076
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .2077
E-24 FUNCTION SWITCH DOES NOT OPERATE .2078
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .2079
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2080
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2081
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .2082
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2083
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .2084
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2085
E-32 ALARM BUZZER CANNOT BE CANCELED 2087
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .2088
E-34 SERVICE MODE CANNOT BE SELECTED 2089
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2090
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .2093
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .2095
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .2098
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .2100
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .2102
E-41 ALARM DOES NOT SOUND DURING TRAVEL .2103
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2105
E-43 HORN DOES NOT SOUND 2106
E-44 HORN DOES NOT STOP SOUNDING 2109
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .2111
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .2112
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2114
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2115
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2116
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2117
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2118
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2119
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2120
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2121
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2122
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2123
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .2125
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .2127
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2128
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2128
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2129
FAILURE MODE AND CAUSE TABLE 2131
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2140
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .2141
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2144
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .2145
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2146
H-6 SPEED OR POWER OF BOOM IS LOW .2148
H-7 ARM SPEED OR POWER IS LOW .2153
H-8 BUCKET SPEED OR POWER IS LOW 2158
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2161
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2162
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2164
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2166
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2167
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2168
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2169
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2170
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2171
H-18 THE SET PRESSURE OF ATTACHMENT IS NOT OUTPUT .2172
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER .2173
H-20 IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY .2174
H-21 IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW 2175
H-22 MACHINE DOES NOT TRAVEL STRAIGHT .2176
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2178
H-24 TRAVEL SPEED IS SLOW .2181
H-25 ONE OF TRACKS DOES NOT RUN .2183
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2184
H-27 MACHINE DOES NOT SWING TO RIGHT OR LEFT 2185
H-28 SWINGS ONLY IN ONE DIRECTION .2186
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT .2187
H-30 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION .2188
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT) 2189
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION) 2190
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION 2191
H-34 THERE IS LARGE UNUSUAL NOISE WHEN IT STOPS SWING OPERATION .2192
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2193
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2194
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT ROTATE) 2195
H-38 THERE IS UNUSUAL NOISE FROM AROUND FAN .2196
TROUBLESHOOTING OF ENGINE (S-MODE) 2197
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2197
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2198
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2199
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2200
S-4 ENGINE STARTABILITY IS POOR .2202
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2204
S-6 ENGINE STOPS DURING OPERATION .2206
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2208
S-8 ENGINE LACKS POWER 2209
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2211
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2213
S-11 OIL BECOMES CONTAMINATED QUICKLY .2214
S-12 FUEL CONSUMPTION IS EXCESSIVE 2215
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2216
S-14 OIL PRESSURE DROPS .2217
S-15 FUEL MIXES INTO ENGINE OIL .2219
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2220
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2221
S-18 UNUSUAL NOISE IS HEARD .2222
S-19 VIBRATION IS EXCESSIVE .2223
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2224
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2225
S-22 ACTIVE REGENERATION TAKES TIME .2227
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2228
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2229
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2231
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2232
50 DISASSEMBLY AND ASSEMBLY .2233
CONTENTS 2234
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2239
HOW TO READ THIS MANUAL .2239
COATING MATERIALS LIST 2241
SPECIAL TOOLS LIST 2245
SKETCHES OF SPECIAL TOOLS .2264
ENGINE AND COOLING SYSTEM .2270
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2270
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2270
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2273
REMOVE AND INSTALL INJECTOR ASSEMBLY 2276
METHOD FOR REMOVING INJECTOR ASSEMBLY .2277
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2282
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2292
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2293
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2302
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2318
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2318
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2319
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2321
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2321
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2324
REMOVE AND INSTALL STARTER ASSEMBLY .2328
METHOD FOR REMOVING STARTER ASSEMBLY 2328
METHOD FOR INSTALLING STARTER ASSEMBLY 2330
REMOVE AND INSTALL ALTERNATOR BELT 2333
METHOD FOR REMOVING ALTERNATOR BELT .2333
METHOD FOR INSTALLING ALTERNATOR BELT .2336
REMOVE AND INSTALL RADIATOR ASSEMBLY 2339
METHOD FOR REMOVING RADIATOR ASSEMBLY .2339
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2342
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2346
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2346
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2353
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2360
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2360
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2362
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2364
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2364
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2369
REMOVE AND INSTALL ENGINE ASSEMBLY 2374
METHOD FOR REMOVING ENGINE ASSEMBLY .2374
METHOD FOR INSTALLING ENGINE ASSEMBLY .2384
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2396
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2396
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2401
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2406
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2406
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2407
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2410
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2410
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2412
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2414
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2414
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2415
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2417
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2417
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2423
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2430
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2431
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2438
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2444
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2445
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2452
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2457
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2457
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2458
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2460
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2460
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2460
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2461
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2461
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2463
REMOVE AND INSTALL KDPF ASSEMBLY 2465
METHOD FOR REMOVING KDPF ASSEMBLY .2466
METHOD FOR INSTALLING KDPF ASSEMBLY .2469
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2473
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2473
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2477
REMOVE AND INSTALL SCR ASSEMBLY .2482
METHOD FOR REMOVING SCR ASSEMBLY 2482
METHOD FOR INSTALLING SCR ASSEMBLY 2483
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2486
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2486
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2496
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2506
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2506
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2507
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2509
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY .2509
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY .2511
REMOVE AND INSTALL KCCV ASSEMBLY 2513
METHOD FOR REMOVING KCCV ASSEMBLY .2513
METHOD FOR INSTALLING KCCV ASSEMBLY .2514
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2515
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2515
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2521
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2526
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2526
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2530
REMOVE AND INSTALL AdBlue/DEF PUMP 2535
METHOD FOR REMOVING AdBlue/DEF PUMP .2535
METHOD FOR INSTALLING AdBlue/DEF PUMP .2539
REMOVE AND INSTALL AdBlue/DEF HOSE 2543
METHOD FOR REMOVING AdBlue/DEF HOSE .2544
METHOD FOR INSTALLING AdBlue/DEF HOSE .2554
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2564
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2564
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2566
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2570
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2570
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2573
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2576
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2576
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2577
POWER TRAIN .2578
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2578
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2578
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2579
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2580
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2581
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2584
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2592
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2592
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2593
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2596
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2596
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2600
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2607
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2607
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2607
UNDERCARRIAGE AND FRAME .2609
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2609
METHOD FOR SEPARATING TRACK ASSEMBLY 2609
METHOD FOR INSTALLING TRACK ASSEMBLY 2610
REMOVE AND INSTALL SPROCKET .2613
METHOD FOR REMOVING SPROCKET 2613
METHOD FOR INSTALLING SPROCKET 2614
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2615
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2615
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2616
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2617
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2617
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2618
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2622
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2622
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2623
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2625
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2625
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2626
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2629
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2629
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2630
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2633
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2633
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2635
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2638
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2638
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2643
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE .2648
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE 2648
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE 2652
HYDRAULIC SYSTEM 2657
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2657
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2657
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2659
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2661
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2661
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2662
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2664
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2664
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2673
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2681
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2681
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2686
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2691
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2692
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2706
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2719
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2719
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2720
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2725
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2725
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2726
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2728
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2728
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2729
WORK EQUIPMENT 2731
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2731
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2731
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2734
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2737
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2738
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2740
CAB AND ITS ATTACHMENTS .2746
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2746
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2746
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2752
REMOVE AND INSTALL OPERATOR’S CAB DOOR 2759
INSTALL OPERATOR’S CAB DOOR .2760
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2764
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2765
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2766
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2775
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2775
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2777
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2783
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2783
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2789
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2795
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2795
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2801
REMOVE AND INSTALL OPERATOR’S SEAT 2808
METHOD FOR REMOVING OPERATOR’S SEAT .2808
METHOD FOR INSTALLING OPERATOR’S SEAT .2809
REMOVE AND INSTALL SEAT BELT 2810
METHOD FOR REMOVING SEAT BELT .2810
METHOD FOR INSTALLING SEAT BELT .2811
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2812
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2812
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2817
ELECTRICAL SYSTEM .2826
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2826
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2826
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2828
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2830
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2830
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2833
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2836
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2836
METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY .2838
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2840
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2840
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2843
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2847
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2847
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2848
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2850
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2850
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2852
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2854
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2854
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2857
REMOVE AND INSTALL KomVision CAMERA .2860
METHOD FOR REMOVING KomVision CAMERA 2860
METHOD FOR INSTALLING KomVision CAMERA 2862
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2865
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2865
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2867
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2869
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY .2869
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2871
REMOVE AND INSTALL COMMUNICATION TERMINAL .2874
REMOVE COMMUNICATION TERMINAL .2874
INSTALL COMMUNICATION TERMINAL 2875
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2877
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 2878
INSTALL COMMUNICATION TERMINAL WIRING HARNESS .2881
60 MAINTENANCE STANDARD .2887
CONTENTS 2888
ENGINE AND COOLING SYSTEM .2889
MAINTENANCE STANDARD OF ENGINE MOUNT 2889
MAINTENANCE STANDARD OF COOLING SYSTEM 2890
POWER TRAIN .2892
MAINTENANCE STANDARD OF SWING CIRCLE 2892
MAINTENANCE STANDARD OF SWING MACHINERY .2893
MAINTENANCE STANDARD OF FINAL DRIVE .2895
MAINTENANCE STANDARD OF SPROCKET 2897
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2898
UNDERCARRIAGE AND FRAME .2900
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2900
MAINTENANCE STANDARD OF IDLER .2902
MAINTENANCE STANDARD OF TRACK ROLLER 2904
MAINTENANCE STANDARD OF CARRIER ROLLER 2906
MAINTENANCE STANDARD OF TRACK SHOE 2907
MAINTENANCE STANDARD OF TRIPLE SHOE .2910
MAINTENANCE STANDARD OF ROAD LINER 2911
MAINTENANCE STANDARD OF FLAT SHOE .2912
HYDRAULIC SYSTEM 2913
MAINTENANCE STANDARD OF HYDRAULIC TANK 2913
MAINTENANCE STANDARD OF MAIN PUMP .2914
MAINTENANCE STANDARD OF LS-EPC VALVE 2915
MAINTENANCE STANDARD OF PC-EPC VALVE 2916
MAINTENANCE STANDARD OF SWING MOTOR .2917
MAINTENANCE STANDARD OF TRAVEL MOTOR 2920
MAINTENANCE STANDARD OF CONTROL VALVE .2923
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2933
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2935
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2937
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2940
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2943
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2945
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2946
MAINTENANCE STANDARD OF SOLENOID VALVE 2948
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2949
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2950
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2951
WORK EQUIPMENT 2952
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2952
DIMENSION OF ARM 2957
DIMENSIONS OF BUCKET 2959
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2961
MAINTENANCE STANDARD OF ARM CYLINDER 2962
MAINTENANCE STANDARD OF BUCKET CYLINDER .2963
80 APPENDIX .2965
CONTENTS 2966
AIR CONDITIONER SYSTEM 2968
PRECAUTIONS FOR REFRIGERANT .2968
AIR CONDITIONER COMPONENT .2969
SPECIFICATIONS OF AIR CONDITIONER .2971
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2972
OUTLINE OF REFRIGERATION CYCLE 2973
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2975
AIR CONDITIONER UNIT 2975
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2975
FUNCTION OF AIR CONDITIONER UNIT 2977
COMPONENT PARTS OF AIR CONDITIONER UNIT .2978
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2978
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2978
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2978
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2978
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2979
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2979
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2979
FUNCTION OF DUAL PRESSURE SWITCH 2980
AIR CONDITIONER CONTROLLER 2981
STRUCTURE OF AIR CONDITIONER CONTROLLER .2981
COMPRESSOR 2982
STRUCTURE OF COMPRESSOR .2982
SPECIFICATIONS OF COMPRESSOR 2982
FUNCTION OF COMPRESSOR 2982
CONDENSER .2983
STRUCTURE OF CONDENSER 2983
SPECIFICATIONS OF CONDENSER .2983
FUNCTION OF CONDENSER .2983
SENSORS FOR AIR CONDITIONER SYSTEM 2985
STRUCTURE OF SUNLIGHT SENSOR 2985
FUNCTION OF SUNLIGHT SENSOR .2985
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2985
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2985
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2987
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2989
AIR CONDITIONER SYSTEM DIAGRAM 2991
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2992
FUNCTION OF AIR CONDITIONER CONTROLLER 2993
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2994
TESTING AIR LEAKAGE (DUCT) 3003
METHOD FOR TESTING AIR LEAKAGE (DUCT) .3003
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .3005
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3006
TEST VENT (MODE) CHANGEOVER .3007
METHOD FOR TESTING VENT (MODE) CHANGEOVER .3007
TESTING FRESH/RECIRC AIR CHANGEOVER .3008
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3008
TEST SUNLIGHT SENSOR 3009
METHOD FOR TESTING SUNLIGHT SENSOR 3009
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3010
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3010
TEST RELAYS .3012
METHOD FOR TESTING RELAYS .3012
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3013
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3014
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3017
FAILURE CODE [879AKA] .3019
FAILURE CODE [879AKB] .3020
FAILURE CODE [879BKA] .3021
FAILURE CODE [879BKB] .3023
FAILURE CODE [879CKA] .3025
FAILURE CODE [879CKB] .3026
FAILURE CODE [879DKZ] .3027
FAILURE CODE [879EMC] .3029
FAILURE CODE [879FMC] .3030
FAILURE CODE [879GKX] .3031
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3033
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3035
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3038
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .3040
TROUBLESHOOTING USING GAUGE PRESSURE 3042
CONNECTION OF SERVICE TOOL 3044
METHOD FOR CONNECTING SERVICE TOOL 3044
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3046
HANDLE COMPRESSOR OIL .3048
METHOD FOR REPLACING DESICCANT 3050
90 CIRCUIT DIAGRAMS .3053
CONTENTS 3054
HOW TO READ THE CODES FOR ELECTRIC CABLE 3055
HYDRAULIC CIRCUIT DIAGRAM .3059
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3059
HYDRAULIC CIRCUIT DIAGRAM (1/5) .3063
HYDRAULIC CIRCUIT DIAGRAM (2/5) .3065
HYDRAULIC CIRCUIT DIAGRAM (3/5) .3067
HYDRAULIC CIRCUIT DIAGRAM (4/5) .3069
HYDRAULIC CIRCUIT DIAGRAM (5/5) .3071
ELECTRICAL CIRCUIT DIAGRAM 3073
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 3073
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (1/8) 3077
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/8) 3079
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/8) 3081
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/8) 3083
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/8) 3085
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/8) 3087
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (7/8) 3089
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (8/8) 3091
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10) 3093
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10) 3095
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10) 3097
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10) 3099
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10) 3101
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10) 3103
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10) 3105
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10) 3107
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10) 3109
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10) .3111
INDEX 3113

DESCRIPTION:

Komatsu PC228USLC-11E0 Hydraulic Excavator Shop Manual UENBM00552 – PDF DOWNLOAD

• SERIAL NUMBERS 6826 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 31/12/24