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KOMATSU PC900LC-11 PC950-11E0 PC950LC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06968-02 – PDF DOWNLOAD
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KOMATSU PC900LC-11 PC950-11E0 PC950LC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06968-02 – PDF DOWNLOAD
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KOMATSU PC900LC-11 PC950-11E0 PC950LC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06968-02 – PDF DOWNLOAD
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KOMATSU PC900LC-11 PC950-11E0 PC950LC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06968-02 – PDF DOWNLOAD
Language : English
Pages : 4094
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC900LC-11 PC950-11E0 PC950LC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06968-02 – PDF DOWNLOAD
Cover................................................................................................................................... 1 00 Index and Foreword.............................................................................................................. 3 Index.......................................................................................................................... 4 Abbreviation List.............................................................................................................. 26 Foreword, Safety, Basic Information............................................................................................ 29 How to Read the Shop Manual................................................................................................ 29 Safety Notice for Operation................................................................................................ 31 Precautions to Prevent Fire................................................................................................ 39 Procedures If Fire Occurs.................................................................................................. 41 Precautions When You Dispose of Waste Materials............................................................................ 42 Procedures for Exhaust Gas Regulations..................................................................................... 43 Precautions for DEF........................................................................................................ 44 General Character and Precautions for Handling......................................................................... 44 Precautions for Adding................................................................................................. 44 Precautions for Storage................................................................................................ 44 Precautions for Fire Hazard and Leakage................................................................................ 44 Other Precautions...................................................................................................... 44 Store DEF.................................................................................................................. 45 Precautions When You Handle Hydraulic Equipment............................................................................ 46 Precautions When You Disconnect and Connect Pipings........................................................................ 49 Precautions When You Handle Electrical Equipment........................................................................... 56 Precautions When You Handle Fuel System Equipment.......................................................................... 58 Precautions When You Handle Intake System Equipment........................................................................ 59 Practical Use of KOMTRAX................................................................................................... 60 Disconnect and Connect Push-Pull Type Coupler.............................................................................. 61 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................ 61 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................ 62 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................ 63 Precautions for Disconnection and Connection of Connectors................................................................. 65 How to Disconnect and Connect Deutsch Connector............................................................................ 69 How to Disconnect and Connect Slide Lock Type Connector.................................................................... 70 How to Disconnect and Connect Connector with Lock to Pull.................................................................. 72 How to Disconnect and Connect Connector with Lock to Push.................................................................. 73 How to Disconnect and Connect Connector with Housing to Rotate............................................................. 75 How to Read the Codes for Electric Cable................................................................................... 76 Explanation of Terms for Maintenance Standard.............................................................................. 80 Standard Tightening Torque Table........................................................................................... 83 Conversion Table........................................................................................................... 90 01 Specifications.................................................................................................................. 95 Table of Contents.............................................................................................................. 96 Specifications................................................................................................................. 97 Specification Drawing...................................................................................................... 97 Specification Drawing: PC900LC-11...................................................................................... 98 Specification Drawing: PC900LC-11(SE).................................................................................. 99 Specification Drawing: PC950-11E0...................................................................................... 100 Specification Drawing: PC950-11E0(SE).................................................................................. 101 Specification Drawing: PC950LC-11E0.................................................................................... 102 Specification Drawing: PC950LC-11E0(SE)................................................................................ 103 Working Range Drawings..................................................................................................... 104 Working Range Drawings: PC900LC-11..................................................................................... 105 Working Range Drawings: PC900LC-11(SE)................................................................................. 106 Working Range Drawings: PC950-11E0..................................................................................... 107 Working Range Drawings: PC950-11E0(SE)................................................................................. 108 Working Range Drawings: PC950LC-11E0................................................................................... 109 Working Range Drawings: PC950LC-11E0(SE)............................................................................... 110 Specifications............................................................................................................. 111 Specifications: PC900LC-11............................................................................................. 112 Specifications: PC900LC-11(SE)......................................................................................... 116 Specifications: PC950-11E0............................................................................................. 120 Specifications: PC950-11E0(SE)......................................................................................... 124 Specifications: PC950LC-11E0........................................................................................... 128 Specifications: PC950LC-11E0(SE)....................................................................................... 132 Weight Table............................................................................................................... 136 Weight Table: PC900LC-11............................................................................................... 137 Weight Table: PC900LC-11(SE)........................................................................................... 139 Weight Table: PC950-11E0............................................................................................... 141 Weight Table: PC950-11E0(SE)........................................................................................... 143 Weight Table: PC950LC-11E0............................................................................................. 145 Weight Table: PC950LC-11E0(SE)......................................................................................... 147 How to Use Fuel, Coolant and Lubricants by Ambient Temperature (PC900LC-11)................................................ 149 How to Use Fuel, Coolant and Lubricants by Ambient Temperature ( PC950-11E0, PC950LC-11E0)................................. 151 10 Structure and Function.......................................................................................................... 153 Table of Contents.............................................................................................................. 154 Urea SCR System................................................................................................................ 158 Layout Drawing of Urea SCR System.......................................................................................... 158 Urea SCR System Diagram.................................................................................................... 162 Function of Urea SCR System................................................................................................ 163 Function of DEF System................................................................................................. 163 Inducement Strategy.................................................................................................... 165 Component Parts of Urea SCR System......................................................................................... 179 DEF Mixing Tube........................................................................................................ 179 SCR Assembly........................................................................................................... 180 DEF Tank............................................................................................................... 182 DEF Pump............................................................................................................... 184 DEF Injector........................................................................................................... 185 DEF Hose............................................................................................................... 186 DEF Tank Heating Valve................................................................................................. 187 Boot-up System................................................................................................................. 188 Layout Drawing of Boot-up System........................................................................................... 188 System Operating Lamp System............................................................................................... 189 System Diagram of System Operating Lamp System......................................................................... 189 Function of Operation Lamp System...................................................................................... 189 Battery Disconnect Switch.................................................................................................. 191 Function of Battery Disconnect Switch.................................................................................. 191 Engine System.................................................................................................................. 192 Layout Drawing of Engine System............................................................................................ 192 Function of Engine System.............................................................................................. 193 Engine Control System...................................................................................................... 194 System Diagram of Engine Control....................................................................................... 194 Function of Engine Control System...................................................................................... 195 Auto-Deceleration System................................................................................................... 197 System Diagram of Auto-Deceleration System............................................................................. 197 Function of Auto-Deceleration System................................................................................... 197 Operation of Auto-Deceleration System.................................................................................. 198 Automatic Low Idle System.................................................................................................. 199 Automatic Low Idle System Diagram...................................................................................... 199 Function of Automatic Low Idle System.................................................................................. 199 Operation of Automatic Low Idle System................................................................................. 200 Engine Automatic Warm-up System............................................................................................ 201 System Diagram of Engine Automatic Warm-up System...................................................................... 201 Function of Engine Automatic Warm-up System............................................................................ 202 Overheat Prevention System................................................................................................. 203 Overheat Prevention System Diagram..................................................................................... 203 Function of Overheat Prevention System................................................................................. 203 Turbocharger Protection System............................................................................................. 205 System Diagram of Turbocharger Protection System....................................................................... 205 Function of Turbocharger Protection System............................................................................. 205 Automatic Idle Stop System................................................................................................. 206 System Diagram of Automatic Idle Stop System........................................................................... 206 Function of Automatic Idle Stop System................................................................................. 206 Component Parts of Engine System........................................................................................... 209 PTO.................................................................................................................... 209 PTO Lubrication System................................................................................................. 211 VGT.................................................................................................................... 213 EGR System............................................................................................................. 217 EGR Valve.............................................................................................................. 219 EGR Cooler............................................................................................................. 221 KCCV System............................................................................................................ 222 KCCV Ventilator........................................................................................................ 224 KDPF................................................................................................................... 226 Cooling System................................................................................................................. 230 Layout Drawing of Cooling System........................................................................................... 230 Specifications of Cooling System....................................................................................... 232 Fan Speed Control System of Hydraulic Fan.................................................................................. 233 Fan Speed Control System Diagram of Hydraulic Fan...................................................................... 233 Function of Fan Speed Control System of Hydraulic Fan.................................................................. 234 Engine Output Control System of Hydraulic Fan.............................................................................. 235 Engine Output Control System Diagram of Hydraulic Fan.................................................................. 235 Function of Engine Output Control System of Hydraulic Fan.............................................................. 235 Fan Reverse Rotation System of Hydraulic Fan............................................................................... 237 Fan Reverse Rotation System Diagram of Hydraulic Fan................................................................... 237 Function of Fan Reverse Rotation System of Hydraulic Fan............................................................... 237 Component Parts of Cooling System.......................................................................................... 239 Cooling Fan Pump of Oil Cooler......................................................................................... 239 Cooling Fan Motor of Radiator.......................................................................................... 247 Cooling Fan Motor of Oil Cooler........................................................................................ 254 Control System................................................................................................................. 262 Layout Drawing of Control System........................................................................................... 262 Machine Monitor System..................................................................................................... 264 System Diagram of Machine Monitor System............................................................................... 264 Function of Machine Monitor System..................................................................................... 266 KomVision System........................................................................................................... 267 Layout Drawing of KomVision System..................................................................................... 267 System Diagram of KomVision System..................................................................................... 269 Function of KomVision System........................................................................................... 270 KOMTRAX System............................................................................................................. 272 System Diagram of KOMTRAX System....................................................................................... 272 Function of KOMTRAX System............................................................................................. 272 Component Parts of Control System.......................................................................................... 273 Machine Monitor........................................................................................................ 273 KomVision Controller................................................................................................... 289 KomVision Camera....................................................................................................... 293 Gateway Function Controller............................................................................................ 294 Communication Terminal................................................................................................. 297 Pump Controller 1...................................................................................................... 299 Pump Controller 2...................................................................................................... 303 Pump Controller 3...................................................................................................... 307 Resistor for Pump Secondary Drive...................................................................................... 311 CAN Terminating Resistor............................................................................................... 312 Engine Controller...................................................................................................... 313 Fuel Control Dial...................................................................................................... 320 Fuel Feed Pump......................................................................................................... 322 Fuel Feed Pump Switch.................................................................................................. 323 Hydraulic System............................................................................................................... 325 Layout Drawing of Hydraulic System......................................................................................... 325 Electronic OLSS............................................................................................................ 328 Structure of Electronic OLSS........................................................................................... 328 Function of Electronic OLSS............................................................................................ 329 Engine and Pump Combined Control System.................................................................................... 331 Engine and Pump Combined Control System Diagram........................................................................ 331 Function of Engine and Pump Combined Control System.................................................................... 332 Component Parts of Hydraulic System........................................................................................ 335 Hydraulic Tank......................................................................................................... 335 Main Pump.............................................................................................................. 337 Control Valve.......................................................................................................... 357 Variable Back Pressure Valve........................................................................................... 384 Counterweight Remover System........................................................................................... 386 Work Equipment System.......................................................................................................... 390 Layout Drawing of Work Equipment System.................................................................................... 390 Work Equipment System Diagram.............................................................................................. 396 Machine Push-up System..................................................................................................... 398 Machine Push-up System Diagram......................................................................................... 398 Function of Machine Push-up System..................................................................................... 398 Boom Shockless Control Function............................................................................................ 400 Boom Shockless Control Function System Diagram......................................................................... 400 Operation of Boom Shockless Control Function........................................................................... 400 PPC Lock System............................................................................................................ 402 System Diagram of PPC Lock............................................................................................. 402 Function of PPC Lock System............................................................................................ 402 Work Equipment and Travel Automatic Lock System............................................................................ 404 System Diagram of Lock Lever Automatic Lock System..................................................................... 404 Function of Work Equipment and Travel Automatic Lock System............................................................ 404 Operation of Lock Lever Automatic Lock System.......................................................................... 405 Component Parts of Work Equipment System................................................................................... 407 Work Equipment and Swing PPC Valve..................................................................................... 407 PPC Shuttle Valve...................................................................................................... 411 Solenoid Valve......................................................................................................... 412 Boom Anti-Drop Valve................................................................................................... 415 Arm Anti-Drop Valve.................................................................................................... 416 Boom Regeneration Valve................................................................................................ 420 Lock Valve............................................................................................................. 423 Quick Return Valve..................................................................................................... 429 Pilot Circuit Accumulator.............................................................................................. 432 Accumulator of Quick Return Circuit.................................................................................... 433 Swing System................................................................................................................... 434 Layout Drawing of Swing System............................................................................................. 434 Swing Control System Diagram............................................................................................... 438 Operation of Swing System.............................................................................................. 439 Function of Swing Control System....................................................................................... 441 Function of Swing Priority and Boom Raise Priority System.............................................................. 443 Component Parts of Swing System............................................................................................ 444 Charge Pump and Radiator Cooling Fan Pump.............................................................................. 444 Swing Pump............................................................................................................. 459 Neutral Hold Valve..................................................................................................... 473 Charge Relief Valve of Electronically Controlled Close Circuit Swing System............................................ 488 Charge Accumulator..................................................................................................... 490 Swing Motor............................................................................................................ 491 Swing Machinery........................................................................................................ 500 Swing Circle........................................................................................................... 502 Travel System.................................................................................................................. 504 Layout Drawing of Travel System............................................................................................ 504 System Diagram of Travel Control System.................................................................................... 507 Function of Travel Control System...................................................................................... 508 Component Parts of Travel System........................................................................................... 509 Straight-Travel Valve.................................................................................................. 509 Travel Motor (PC900LC-11).............................................................................................. 513 Travel Motor (PC950-11E0, PC950LC-11E0)................................................................................ 525 Final Drive (PC900LC-11)............................................................................................... 537 Final Drive (PC950-11E0, PC950LC-11E0)................................................................................. 540 Travel PPC Valve....................................................................................................... 542 Center Swivel Joint.................................................................................................... 546 Undercarriage and Frame........................................................................................................ 548 Layout Drawing of Undercarriage............................................................................................ 548 Specifications of Undercarriage (PC900LC-11)........................................................................... 548 Specifications of Undercarriage (PC950-11E0, PC950LC-11E0)............................................................. 549 Work Equipment................................................................................................................. 550 Structure of Work Equipment................................................................................................ 550 Function of Work Equipment................................................................................................. 551 Work Equipment Clearance Adjustment Shim................................................................................... 552 Function of Work Equipment Clearance Adjustment Shim................................................................... 552 Bucket Clearance Adjustment Shim........................................................................................... 553 Function of Bucket Clearance Adjustment Shim........................................................................... 553 CAB Related Parts.............................................................................................................. 554 CAB........................................................................................................................ 554 Structure of CAB....................................................................................................... 554 CAB Mount.................................................................................................................. 555 Structure of CAB Mount................................................................................................. 555 Function of CAB Mount.................................................................................................. 555 CAB Tipping Stopper........................................................................................................ 556 Structure of CAB Tipping Stopper....................................................................................... 556 Function of CAB Tipping Stopper........................................................................................ 556 20 Standard Value Table............................................................................................................ 557 Table of Contents.............................................................................................................. 558 Standard Value Table for Engine................................................................................................ 559 Standard Value Table for Engine: PC900LC-11................................................................................ 559 Standard Value Table for Engine: PC900LC-11(SE)............................................................................ 563 Standard Value Table for Engine: PC950-11E0................................................................................ 567 Standard Value Table for Engine: PC950-11E0(SE)............................................................................ 571 Standard Value Table for Engine: PC950LC-11E0.............................................................................. 575 Standard Value Table for Engine: PC950LC-11E0(SE).......................................................................... 579 Standard Value Table for Machine............................................................................................... 583 Standard Value Table for Machine: PC900LC-11............................................................................... 583 Standard Value Table for Machine: PC900LC-11(SE)........................................................................... 602 Standard Value Table for Machine: PC950-11E0 (EU Specifications)........................................................... 621 Standard Value Table for Machine: PC950-11E0 (Turkish Specifications)...................................................... 639 Standard Value Table for Machine: PC950-11E0 (SE) (EU Specifications)...................................................... 657 Standard Value Table for Machine: PC950-11E0 (SE) (Turkish Specifications)................................................. 675 Standard Value Table for Machine: PC950LC-11E0 (EU Specifications)......................................................... 693 Standard Value Table for Machine: PC950LC-11E0 (Turkish Specifications).................................................... 711 Standard Value Table for Machine: PC950LC-11E0 (SE) (EU Specifications).................................................... 729 Standard Value Table for Machine: PC950LC-11E0 (SE) (Turkish Specifications)............................................... 747 Machine Posture and Procedures to Measure Performance...................................................................... 765 30 Testing and Adjusting........................................................................................................... 769 Table of Contents.............................................................................................................. 770 Precautions Before Work........................................................................................................ 774 Related Information on Testing and Adjusting................................................................................... 775 Tools for Testing and Adjusting............................................................................................ 775 Sketch of Tools for Testing and Adjusting.................................................................................. 785 Engine and Cooling System...................................................................................................... 787 Examine Engine Speed....................................................................................................... 787 How to Examine Engine Speed............................................................................................ 787 Examine Boost Pressure..................................................................................................... 790 How to Examine Boost Pressure on Machine Monitor....................................................................... 790 How to Examine Boost Pressure by Testing Tool.......................................................................... 791 Examine Exhaust Gas Temperature............................................................................................ 793 How to Examine Exhaust Gas Temperature................................................................................. 793 Examine Mass Air Flow and Temperature Sensor............................................................................... 795 How to Examine Mass Air Flow and Temperature Sensor.................................................................... 795 Examine Exhaust Gas Color.................................................................................................. 797 How to Examine Exhaust Gas Color with the Handy Smoke Checker.......................................................... 797 How to Examine Exhaust Gas Color with Smoke Meter...................................................................... 798 Examine and Adjust Valve Clearance......................................................................................... 800 How to Examine Valve Clearance......................................................................................... 800 How to Adjust Valve Clearance.......................................................................................... 801 Examine Compression Pressure............................................................................................... 803 How to Examine Compression Pressure.................................................................................... 803 Examine Blowby Pressure.................................................................................................... 806 How to Examine Blowby Pressure......................................................................................... 806 Examine Engine Oil Pressure................................................................................................ 808 How to Examine Engine Oil Pressure on Machine Monitor.................................................................. 808 How to Examine Engine Oil Pressure by Testing Tool..................................................................... 808 Examine EGR Valve and VGT Oil Pressure..................................................................................... 810 How to Examine EGR Valve and VGT Oil Pressure.......................................................................... 810 Examine Fuel Pressure...................................................................................................... 812 How to Examine Fuel Pressure........................................................................................... 812 Examine Fuel Return Rate and Leakage....................................................................................... 814 How to Examine Fuel Return Rate and Leakage............................................................................ 814 Bleed Air from Fuel System................................................................................................. 817 How to Bleed Air from Fuel System...................................................................................... 817 Examine Fuel Circuit for Leakage........................................................................................... 819 How to Examine Fuel System for Leakage................................................................................. 819 Handle Cylinder Cut-out Mode Operation..................................................................................... 821 Handle No-Injection Cranking Operation..................................................................................... 822 Clean Fuel Doser........................................................................................................... 823 How to Clean Fuel Doser................................................................................................ 823 Write Injector Compensation Value to Engine Controller..................................................................... 825 How to Write Injector Compensation Value............................................................................... 825 Write Correction for Ash in Soot Accumulation to Engine Controller......................................................... 831 How to Write Correction for Ash in Soot Accumulation to Engine Controller.............................................. 831 Examine SCR Related Functions.............................................................................................. 832 Examine DEF Pump Raised Pressure....................................................................................... 836 Examine Injection Volume from DEF Injector............................................................................. 839 Examine DEF Line Heater Relay 1........................................................................................ 844 Examine DEF Line Heater Relay 2........................................................................................ 847 Examine DEF Pump Heater Relay.......................................................................................... 850 Examine DEF Tank Heater Valve.......................................................................................... 853 Examine SCR Denitration Efficiency..................................................................................... 856 Clean DEF Tank............................................................................................................. 860 How to Clean DEF Tank.................................................................................................. 860 Power Train.................................................................................................................... 864 Examine Swing Circle Bearing Clearance..................................................................................... 864 How to Examine Swing Circle Bearing Clearance.......................................................................... 864 Undercarriage and Frame........................................................................................................ 866 Examine and Adjust Track Tension........................................................................................... 866 How to Examine Track Tension........................................................................................... 866 How to Adjust Track Tension............................................................................................ 866 Hydraulic System............................................................................................................... 868 Release Remained Pressure in Hydraulic Circuit............................................................................. 868 How to Release Remained Pressure in Hydraulic System................................................................... 868 How to Release Remained Pressure from Swing Motor Circuit.............................................................. 876 How to Release Remained Pressure from Travel Motor Circuit............................................................. 877 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits.............................................. 878 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits.............................................. 878 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits............................................... 884 Examine and Adjust Oil Pressure in Control Circuit......................................................................... 886 How to Examine Oil Pressure in Control Circuit......................................................................... 886 How to Adjust Oil Pressure in Control Circuit.......................................................................... 887 Examine Pump EPC Solenoid Valve Outlet Pressure............................................................................ 888 How to Examine Pump EPC Solenoid Valve Outlet Pressure................................................................. 888 How to Examine Pump EPC Solenoid Valve Electric Current................................................................ 889 Examine and Adjust Jet Sensor Differential Pressure........................................................................ 890 How to Examine Jet Sensor Differential Pressure with Machine Monitor................................................... 890 How to Examine Jet Sensor Differential Pressure by Testing Tool........................................................ 891 How to Adjust Jet Sensor Differential Pressure......................................................................... 892 How to Test Jet Sensor Differential Pressure Sensor Volt............................................................... 892 Test and Adjust Swing Oil Pressure......................................................................................... 894 How to Test Swing Oil Pressure......................................................................................... 894 How to Adjust Swing Oil Pressure....................................................................................... 897 Bleed Air from Swing Pump.................................................................................................. 900 How to Bleed Air from Swing Pump....................................................................................... 900 How to Bleed Air from Servo Valve of Swing Pump........................................................................ 900 Test Outlet Pressure of Swing Neutral Hold Valve EPC Solenoid Valve........................................................ 901 How to Test Outlet Pressure of Swing Neutral Hold Valve EPC Solenoid Valve............................................. 901 How to Test Swing Neutral Hold Valve EPC Solenoid Valve Current........................................................ 902 How to Test Swing Neutral Hold Valve Stroke Sensor..................................................................... 902 Open Swing Junction Valve When Swing Operation Cannot be Operated.......................................................... 903 How to Open Swing Junction Valve When Swing Operation Cannot be Operated............................................... 903 Examine Outlet Pressure of Solenoid Valve.................................................................................. 904 How to Examine Outlet Pressure of Solenoid Valve....................................................................... 904 Operating Condition of Solenoid Valve.................................................................................. 906 Examine Outlet Pressure of EPC Solenoid Valve.............................................................................. 908 How to Examine Outlet Pressure of EPC Solenoid Valve................................................................... 908 Examine PPC Valve Outlet Pressure.......................................................................................... 910 How to Examine PPC Valve Outlet Pressure............................................................................... 911 Adjust Play of Work Equipment and Swing PPC Valves......................................................................... 913 How to Adjust Play of Work Equipment and Swing PPC Valves.............................................................. 913 Examine Travel Deviation................................................................................................... 914 How to Examine Travel Deviation........................................................................................ 914 How to Adjust Travel Deviation......................................................................................... 914 Examine Fan Speed.......................................................................................................... 915 How to Examine Radiator Fan Speed...................................................................................... 915 How to Examine Oil Cooler Fan Speed.................................................................................... 915 Examine Oil Pressure in Fan Pump Circuit................................................................................... 916 How to Examine Radiator Fan Pump Circuit Oil Pressure by Machine Monitor............................................... 916 How to Examine Radiator Fan Pump Circuit Oil Pressure by Testing Tool.................................................. 916 How to Examine Oil Cooler Fan Pump Circuit Oil Pressure by Machine Monitor............................................. 917 How to Examine Oil Cooler Fan Pump Circuit Oil Pressure by Testing Tool................................................ 917 Examine Fan Pump EPC Electric Current...................................................................................... 919 How to Examine Radiator Fan Pump EPC Electric Current.................................................................. 919 How to Examine Oil Cooler Fan Pump EPC Electric Current................................................................ 919 Examine Fan Pump EPC Solenoid Valve Outlet Pressure........................................................................ 920 How to Examine Radiator Fan Pump EPC Solenoid Valve Outlet Pressure.................................................... 920 How to Examine Outlet Pressure of EPC Solenoid Valve of Oil Cooler Fan Pump............................................ 921 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................ 922 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder.................................. 922 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder................................................... 922 How to Examine Parts that Cause Hydraulic Drift of PPC Valve........................................................... 923 Examine Oil Leakage........................................................................................................ 924 How to Examine Oil Leakage from Boom Cylinder.......................................................................... 924 How to Examine Oil Leakage from Arm Cylinder........................................................................... 925 How to Examine Oil Leakage from Bucket Cylinder........................................................................ 925 How to Examine Oil Leakage from Swing Motor............................................................................ 926 How to Examine Oil Leakage from Travel Motor........................................................................... 926 How to Examine Oil Leakage of Swivel Joint............................................................................. 927 How to Examine Oil Leakage from Counterweight Remover Cylinder......................................................... 930 Bleed Air from Hydraulic System............................................................................................ 933 How to Bleed Air from Hydraulic System................................................................................. 934 CAB Related Parts.............................................................................................................. 938 Examine CAB Tipping Stopper................................................................................................ 938 How to Examine Cab Tipping Stopper..................................................................................... 938 How to Adjust Mirrors...................................................................................................... 939 Procedure to Adjust Machine Left Front Mirror (A)...................................................................... 940 Procedure to Adjust Regular Position of Machine Left Front Mirror (A).................................................. 940 Procedure to Adjust Right Front Mirror (B)............................................................................. 942 Procedure to Adjust Regular Position of Machine Right Front Mirror (B)................................................. 943 Procedure to Adjust Right Front Mirror (C)............................................................................. 944 Procedure to Adjust Regular Position of Machine Right Front Mirror (C)................................................. 945 Electrical System.............................................................................................................. 947 Set and Operate Machine Monitor............................................................................................ 947 Operator Mode.......................................................................................................... 951 Function to Show Technician Identification Status Screen............................................................... 951 Function to Show Operator Identification Input Screen.................................................................. 951 Examine Function by LCD (Liquid Crystal Display)....................................................................... 952 Examine Function of Service Meter...................................................................................... 952 Usage Limitation and Maintenance Password Change Function.............................................................. 952 Service Mode........................................................................................................... 955 How to Operate Service Mode............................................................................................ 955 How to See Pre-defined Monitoring Information.......................................................................... 958 How to Examine Self-Define Monitor Information......................................................................... 962 Abnormality Record Menu................................................................................................ 979 How to See Maintenance Record.......................................................................................... 983 Maintenance Mode Setting............................................................................................... 985 How to Set Phone Number Entry.......................................................................................... 989 Default Menu........................................................................................................... 991 Diagnostic Tests Menu..................................................................................................1001 Adjustment Menu........................................................................................................1011 Machine Configuration Menu.............................................................................................1058 No-Injection Cranking Operation........................................................................................1060 KOMTRAX Settings Menu..................................................................................................1062 How to Show Service Message............................................................................................1064 How to Start Up KOMTRAX System (Machine with Gateway Function Controller)..................................................1066 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)...............................................1072 Adjust Rearview Camera Angle...............................................................................................1074 How to Adjust Rearview Camera Angle....................................................................................1074 Adjust KomVision Camera Angle..............................................................................................1076 How to Adjust KomVision Camera Angle...................................................................................1077 Adjust KomVision Related Function..........................................................................................1079 Setting of KomVision (Main Setting)....................................................................................1080 Setting of KomVision (Camera Setting)..................................................................................1082 Setting of KomVision (Camera Calibration)..............................................................................1083 KomVision screen - Check 12 m visibility...............................................................................1096 Handle Voltage Circuit of Engine Controller................................................................................1099 Handle Battery Disconnect Switch...........................................................................................1100 Examine Diodes.............................................................................................................1101 How to Examine Diodes by Digital Tester................................................................................1101 How to Examine Diodes by Analog Tester.................................................................................1101 Pm Clinic......................................................................................................................1102 Pm Clinic Service..........................................................................................................1102 Pm Clinic Check Sheet: PC900LC-11......................................................................................1106 Pm Clinic Check Sheet: PC900LC-11(SE)..................................................................................1119 Pm Clinic Check Sheet: PC950-11E0 (EU Specifications)..................................................................1132 Pm Clinic Check Sheet: PC950-11E0 (Turkish Specifications).............................................................1145 Pm Clinic Check Sheet: PC950-11E0 (SE) (EU Specifications).............................................................1158 Pm Clinic Check Sheet: PC950-11E0 (SE) (Turkish Specifications)........................................................1171 Pm Clinic Check Sheet: PC950LC-11E0 (EU Specifications)................................................................1184 Pm Clinic Check Sheet: PC950LC-11E0 (Turkish Specifications)...........................................................1197 Pm Clinic Check Sheet: PC950LC-11E0 (SE) (EU Specifications)...........................................................1210 Pm Clinic Check Sheet: PC950LC-11E0 (SE) (Turkish Specifications)......................................................1223 40 Troubleshooting.................................................................................................................1237 Table of Contents..............................................................................................................1238 Precautions Before Work........................................................................................................1252 Related Information to Troubleshooting.........................................................................................1253 General Troubleshooting Points.............................................................................................1253 Troubleshooting Points for Aftertreatment System...........................................................................1254 Sequence of Events in Troubleshooting......................................................................................1266 Checks Before Troubleshooting..............................................................................................1268 Inspection Procedure Before Troubleshooting................................................................................1270 Walk-Around Check......................................................................................................1270 Test in Accordance with Testing Procedure..................................................................................1272 Examine Fuel Level and Type............................................................................................1272 Examine for Impure Ingredient in Fuel..................................................................................1272 Examine Fuel Prefilter.................................................................................................1273 Examine Water Separator, Drain Water and Sediment......................................................................1273 How to Examine Water Separator, Drain Water and Sediment (Machine with Large Capacity Prefilter).......................1274 Replace Fuel Prefilter Cartridge.......................................................................................1274 How to Replace Fuel Prefilter Cartridge (Machine with Large Capacity Prefilter)........................................1276 Examine Fuel Main Filter...............................................................................................1277 Examine Engine Oil Level (Oil Quantity in Oil Pan).....................................................................1278 Examine Coolant Level (Expansion Tank).................................................................................1280 How to Replace Coolant Filter Cartridge................................................................................1281 Examine Air Cleaner Clogging...........................................................................................1281 Clean Outer Element....................................................................................................1282 Replace Element........................................................................................................1285 Check Hydraulic Oil Level..............................................................................................1286 Examine Hydraulic Oil Strainer.........................................................................................1287 Examine Hydraulic Oil Filter...........................................................................................1288 Examine Oil Level in Swing Machinery Case..............................................................................1289 Examine Oil Level in PTO Case..........................................................................................1291 Examine PTO Lubrication Filter Strainer................................................................................1291 Examine Oil Level in Final Drive Case (PC900LC-11).....................................................................1292 Examine Oil Level in Final Drive Case (PC950-11E0,PC950LC-11E0)........................................................1292 Bleed Air from Fuel System.............................................................................................1293 Bleed Air from Hydraulic System........................................................................................1293 How to Examine Electrical Components...................................................................................1293 Preparation for Troubleshooting of Electrical System.......................................................................1299 Preparation for Troubleshooting of Machine Monitor.....................................................................1299 Preparation for Troubleshooting of Engine Controller...................................................................1299 Preparation for Troubleshooting of Pump Controller.....................................................................1299 Preparation for Troubleshooting of Gateway Function Controller.........................................................1300 How to Disconnect and Connect Connector with a Special Lock............................................................1300 Procedure for Troubleshooting..............................................................................................1304 Symptom and Troubleshooting Numbers........................................................................................1307 Information Shown in Troubleshooting Table.................................................................................1311 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness............................................1313 Connectors List (PC900LC-11)...............................................................................................1316 Connector Layout (PC900LC-11)..............................................................................................1327 Connectors List (PC950-11E0, PC950LC-11E0).................................................................................1340 Connector Layout (PC950-11E0, PC950LC-11E0)................................................................................1351 Connector Contact Connection Table.........................................................................................1364 T-Branch Box and T-Branch Adapter Table....................................................................................1404 Fuse Location Table........................................................................................................1410 Precautions When You Clean and Replace KDPF (KCSF and KDOC)................................................................1414 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]).......................................1418 Failure Code Table.........................................................................................................1420 Troubleshooting by Failure Code (Display of Code)..............................................................................1446 Failure Code [60D2NX]......................................................................................................1446 Failure Code [879AKA]......................................................................................................1448 Failure Code [879AKB]......................................................................................................1449 Failure Code [879BKA]......................................................................................................1450 Failure Code [879BKB]......................................................................................................1452 Failure Code [879CKA]......................................................................................................1454 Failure Code [879CKB]......................................................................................................1455 Failure Code [879DKZ]......................................................................................................1456 Failure Code [879EMC]......................................................................................................1458 Failure Code [879FMC]......................................................................................................1459 Failure Code [879GKX]......................................................................................................1460 Failure Code [8800ZG]......................................................................................................1462 Failure Code [A1U0N3]......................................................................................................1463 Failure Code [A1U0N4]......................................................................................................1465 Failure Code [A900FR]......................................................................................................1467 Failure Code [A900N6]......................................................................................................1468 Failure Code [A900NY]......................................................................................................1469 Failure Code [AA10NX]......................................................................................................1470 Failure Code [AB00KE]......................................................................................................1472 Failure Code [AQ10N3]......................................................................................................1474 Failure Code [AS00N3]......................................................................................................1476 Failure Code [AS00R2]......................................................................................................1478 Failure Code [AS00R3]......................................................................................................1479 Failure Code [AS00R4]......................................................................................................1480 Failure Code [AS00R5]......................................................................................................1481 Failure Code [AS00R6]......................................................................................................1482 Failure Code [AS00ZK]......................................................................................................1483 Failure Code [AS10KM]......................................................................................................1484 Failure Code [AS10NR]......................................................................................................1485 Failure Code [AS10NT]......................................................................................................1486 Failure Code [B@BAZG]......................................................................................................1487 Failure Code [B@BAZK]......................................................................................................1488 Failure Code [B@BCNS]......................................................................................................1490 Failure Code [B@BCQA]......................................................................................................1491 Failure Code [B@BCZK]......................................................................................................1493 Failure Code [B@HANS]......................................................................................................1495 Failure Code [CA115].......................................................................................................1496 Failure Code [CA122].......................................................................................................1497 Failure Code [CA123].......................................................................................................1499 Failure Code [CA131].......................................................................................................1501 Failure Code [CA132].......................................................................................................1503 Failure Code [CA135].......................................................................................................1505 Failure Code [CA141].......................................................................................................1507 Failure Code [CA144].......................................................................................................1509 Failure Code [CA145].......................................................................................................1511 Failure Code [CA153].......................................................................................................1513 Failure Code [CA154].......................................................................................................1516 Failure Code [CA187].......................................................................................................1519 Failure Code [CA221].......................................................................................................1521 Failure Code [CA222].......................................................................................................1524 Failure Code [CA227].......................................................................................................1527 Failure Code [CA234].......................................................................................................1528 Failure Code [CA238].......................................................................................................1529 Failure Code [CA239].......................................................................................................1530 Failure Code [CA249].......................................................................................................1532 Failure Code [CA256].......................................................................................................1534 Failure Code [CA271].......................................................................................................1536 Failure Code [CA272].......................................................................................................1538 Failure Code [CA273].......................................................................................................1539 Failure Code [CA274].......................................................................................................1541 Failure Code [CA322].......................................................................................................1542 Failure Code [CA323].......................................................................................................1544 Failure Code [CA324].......................................................................................................1546 Failure Code [CA325].......................................................................................................1548 Failure Code [CA331].......................................................................................................1550 Failure Code [CA332].......................................................................................................1552 Failure Code [CA343].......................................................................................................1554 Failure Code [CA351].......................................................................................................1555 Failure Code [CA352].......................................................................................................1556 Failure Code [CA356].......................................................................................................1559 Failure Code [CA357].......................................................................................................1561 Failure Code [CA386].......................................................................................................1563 Failure Code [CA441].......................................................................................................1564 Failure Code [CA442].......................................................................................................1566 Failure Code [CA449].......................................................................................................1567 Failure Code [CA451].......................................................................................................1568 Failure Code [CA452].......................................................................................................1570 Failure Code [CA515].......................................................................................................1572 Failure Code [CA516].......................................................................................................1574 Failure Code [CA553].......................................................................................................1576 Failure Code [CA555].......................................................................................................1577 Failure Code [CA556].......................................................................................................1578 Failure Code [CA559].......................................................................................................1579 Failure Code [CA595].......................................................................................................1584 Failure Code [CA687].......................................................................................................1585 Failure Code [CA689].......................................................................................................1587 Failure Code [CA691].......................................................................................................1590 Failure Code [CA692].......................................................................................................1592 Failure Code [CA697].......................................................................................................1594 Failure Code [CA698].......................................................................................................1595 Failure Code [CA731].......................................................................................................1596 Failure Code [CA778].......................................................................................................1597 Failure Code [CA1117]......................................................................................................1600 Failure Code [CA1664]......................................................................................................1601 Failure Code [CA1669]......................................................................................................1605 Failure Code [CA1673]......................................................................................................1606 Failure Code [CA1677]......................................................................................................1607 Failure Code [CA1678]......................................................................................................1608 Failure Code [CA1682]......................................................................................................1609 Failure Code [CA1683]......................................................................................................1614 Failure Code [CA1684]......................................................................................................1616 Failure Code [CA1686]......................................................................................................1618 Failure Code [CA1691]......................................................................................................1619 Failure Code [CA1694]......................................................................................................1622 Failure Code [CA1695]......................................................................................................1624 Failure Code [CA1696]......................................................................................................1625 Failure Code [CA1712]......................................................................................................1627 Failure Code [CA1713]......................................................................................................1630 Failure Code [CA1714]......................................................................................................1632 Failure Code [CA1715]......................................................................................................1633 Failure Code [CA1776]......................................................................................................1634 Failure Code [CA1777]......................................................................................................1637 Failure Code [CA1843]......................................................................................................1640 Failure Code [CA1844]......................................................................................................1642 Failure Code [CA1879]......................................................................................................1645 Failure Code [CA1881]......................................................................................................1647 Failure Code [CA1883]......................................................................................................1649 Failure Code [CA1885]......................................................................................................1653 Failure Code [CA1887]......................................................................................................1655 Failure Code [CA1921]......................................................................................................1657 Failure Code [CA1922]......................................................................................................1663 Failure Code [CA1923]......................................................................................................1669 Failure Code [CA1924]......................................................................................................1671 Failure Code [CA1925]......................................................................................................1674 Failure Code [CA1927]......................................................................................................1676 Failure Code [CA1928]......................................................................................................1678 Failure Code [CA1942]......................................................................................................1680 Failure Code [CA1963]......................................................................................................1681 Failure Code [CA1977]......................................................................................................1685 Failure Code [CA1993]......................................................................................................1688 Failure Code [CA2185]......................................................................................................1691 Failure Code [CA2186]......................................................................................................1693 Failure Code [CA2249]......................................................................................................1695 Failure Code [CA2265]......................................................................................................1696 Failure Code [CA2266]......................................................................................................1698 Failure Code [CA2271]......................................................................................................1700 Failure Code [CA2272]......................................................................................................1702 Failure Code [CA2349]......................................................................................................1705 Failure Code [CA2353]......................................................................................................1707 Failure Code [CA2357]......................................................................................................1709 Failure Code [CA2381]......................................................................................................1710 Failure Code [CA2382]......................................................................................................1712 Failure Code [CA2383]......................................................................................................1714 Failure Code [CA2386]......................................................................................................1716 Failure Code [CA2387]......................................................................................................1718 Troubleshooting Flowchart..............................................................................................1722 Failure Code [CA2555]......................................................................................................1723 Failure Code [CA2556]......................................................................................................1725 Failure Code [CA2637]......................................................................................................1727 Failure Code [CA2639]......................................................................................................1730 Failure Code [CA2732]......................................................................................................1733 Failure Code [CA2733]......................................................................................................1735 Failure Code [CA2741]......................................................................................................1737 Failure Code [CA2765]......................................................................................................1739 Failure Code [CA2771]......................................................................................................1740 Failure Code [CA2777]......................................................................................................1746 Failure Code [CA2878]......................................................................................................1749 Failure Code [CA2881]......................................................................................................1752 Failure Code [CA2976]......................................................................................................1755 Failure Code [CA3133]......................................................................................................1757 Failure Code [CA3134]......................................................................................................1759 Failure Code [CA3135]......................................................................................................1761 Failure Code [CA3142]......................................................................................................1764 Failure Code [CA3143]......................................................................................................1765 Failure Code [CA3144]......................................................................................................1766 Failure Code [CA3146]......................................................................................................1768 Failure Code [CA3147]......................................................................................................1769 Failure Code [CA3148]......................................................................................................1770 Failure Code [CA3151]......................................................................................................1772 Failure Code [CA3165]......................................................................................................1777 Failure Code [CA3167]......................................................................................................1780 Failure Code [CA3228]......................................................................................................1784 Failure Code [CA3229]......................................................................................................1787 Failure Code [CA3231]......................................................................................................1790 Failure Code [CA3232]......................................................................................................1793 Failure Code [CA3235]......................................................................................................1798 Failure Code [CA3239]......................................................................................................1800 Failure Code [CA3241]......................................................................................................1803 Failure Code [CA3242]......................................................................................................1806 Failure Code [CA3251]......................................................................................................1809 Failure Code [CA3253]......................................................................................................1813 Failure Code [CA3254]......................................................................................................1819 Failure Code [CA3255]......................................................................................................1823 Failure Code [CA3256]......................................................................................................1827 Failure Code [CA3311]......................................................................................................1831 Failure Code [CA3312]......................................................................................................1835 Failure Code [CA3313]......................................................................................................1839 Failure Code [CA3314]......................................................................................................1842 Failure Code [CA3315]......................................................................................................1845 Failure Code [CA3316]......................................................................................................1848 Failure Code [CA3317]......................................................................................................1849 Failure Code [CA3318]......................................................................................................1850 Failure Code [CA3319]......................................................................................................1853 Failure Code [CA3321]......................................................................................................1854 Failure Code [CA3322]......................................................................................................1855 Failure Code [CA3419]......................................................................................................1858 Failure Code [CA3421]......................................................................................................1860 Failure Code [CA3497]......................................................................................................1862 Failure Code [CA3498]......................................................................................................1863 Failure Code [CA3543]......................................................................................................1864 Failure Code [CA3545]......................................................................................................1869 Failure Code [CA3547]......................................................................................................1871 Failure Code [CA3558]......................................................................................................1872 Failure Code [CA3559]......................................................................................................1874 Failure Code [CA3562]......................................................................................................1876 Failure Code [CA3563]......................................................................................................1878 Failure Code [CA3567]......................................................................................................1881 Failure Code [CA3568]......................................................................................................1884 Failure Code [CA3571]......................................................................................................1888 Failure Code [CA3572]......................................................................................................1890 Failure Code [CA3574]......................................................................................................1892 Failure Code [CA3575]......................................................................................................1895 Failure Code [CA3577]......................................................................................................1897 Failure Code [CA3578]......................................................................................................1899 Failure Code [CA3582]......................................................................................................1901 Failure Code [CA3583]......................................................................................................1906 Failure Code [CA3596]......................................................................................................1909 Failure Code [CA3649]......................................................................................................1913 Failure Code [CA3681]......................................................................................................1916 Failure Code [CA3682]......................................................................................................1921 Failure Code [CA3713]......................................................................................................1927 Failure Code [CA3717]......................................................................................................1930 Failure Code [CA3718]......................................................................................................1931 Failure Code [CA3725]......................................................................................................1932 Failure Code [CA3741]......................................................................................................1935 Failure Code [CA3748]......................................................................................................1936 Failure Code [CA3751]......................................................................................................1938 Failure Code [CA3755]......................................................................................................1940 Failure Code [CA3866]......................................................................................................1942 Failure Code [CA3867]......................................................................................................1946 Failure Code [CA3868]......................................................................................................1949 Failure Code [CA3899]......................................................................................................1953 Failure Code [CA3911]......................................................................................................1956 Failure Code [CA3912]......................................................................................................1960 Failure Code [CA3932]......................................................................................................1962 Failure Code [CA3933]......................................................................................................1964 Failure Code [CA3934]......................................................................................................1966 Failure Code [CA3935]......................................................................................................1969 Failure Code [CA3936]......................................................................................................1971 Failure Code [CA4151]......................................................................................................1973 Failure Code [CA4152]......................................................................................................1977 Failure Code [CA4155]......................................................................................................1981 Failure Code [CA4156]......................................................................................................1984 Failure Code [CA4157]......................................................................................................1987 Failure Code [CA4158]......................................................................................................1989 Failure Code [CA4159]......................................................................................................1991 Failure Code [CA4161]......................................................................................................1993 Failure Code [CA4162]......................................................................................................1996 Failure Code [CA4163]......................................................................................................1999 Failure Code [CA4164]......................................................................................................2002 Failure Code [CA4165]......................................................................................................2004 Failure Code [CA4166]......................................................................................................2006 Failure Code [CA4168]......................................................................................................2008 Failure Code [CA4169]......................................................................................................2013 Failure Code [CA4171]......................................................................................................2018 Failure Code [CA4249]......................................................................................................2023 Failure Code [CA4251]......................................................................................................2028 Failure Code [CA4259]......................................................................................................2033 Failure Code [CA4261]......................................................................................................2036 Failure Code [CA4277]......................................................................................................2039 Failure Code [CA4281]......................................................................................................2042 Failure Code [CA4459]......................................................................................................2045 Failure Code [CA4461]......................................................................................................2048 Failure Code [CA4731]......................................................................................................2051 Failure Code [CA4732]......................................................................................................2052 Failure Code [CA4739]......................................................................................................2053 Failure Code [CA4768]......................................................................................................2054 Failure Code [CA4769]......................................................................................................2056 Failure Code [CA4842]......................................................................................................2058 Failure Code [CA4952]......................................................................................................2061 Failure Code [CA5115]......................................................................................................2063 Failure Code [CA5179]......................................................................................................2066 Failure Code [CA5181]......................................................................................................2068 Failure Code [CA5383]......................................................................................................2070 Failure Code [D110KB]......................................................................................................2072 Failure Code [D163KB]......................................................................................................2074 Failure Code [D195KA]......................................................................................................2076 Failure Code [D195KB]......................................................................................................2078 Failure Code [D19JKZ]......................................................................................................2080 Failure Code [D19UFS]......................................................................................................2082 Failure Code [D19UKA]......................................................................................................2083 Failure Code [D19UKB]......................................................................................................2085 Failure Code [D19UKY]......................................................................................................2087 Failure Code [D1ETKB]......................................................................................................2088 Failure Code [D1F0KA]......................................................................................................2090 Failure Code [D1F0KB]......................................................................................................2091 Failure Code [D1F0KY]......................................................................................................2092 Failure Code [D1S1KA]......................................................................................................2093 Failure Code [D1S1KB]......................................................................................................2094 Failure Code [D1S1KY]......................................................................................................2096 Failure Code [D811MC]......................................................................................................2097 Failure Code [D862KA]......................................................................................................2098 Failure Code [D8ALKA]......................................................................................................2100 Failure Code [D8ALKB]......................................................................................................2102 Failure Code [D8AQKR]......................................................................................................2104 Failure Code [D8ARKR]......................................................................................................2111 Failure Code [D8G1KT]......................................................................................................2116 Failure Code [D8G6KT]......................................................................................................2117 Failure Code [DA20MC]......................................................................................................2118 Failure Code [DA22KK]......................................................................................................2119 Failure Code [DA22KT]......................................................................................................2121 Failure Code [DA25KP]......................................................................................................2122 Failure Code [DA26KP]......................................................................................................2125 Failure Code [DA29KQ]......................................................................................................2127 Failure Code [DA2LKA]......................................................................................................2129 Failure Code [DA2LKB]......................................................................................................2131 Failure Code [DA2QKR]......................................................................................................2133 Failure Code [DA2RKR]......................................................................................................2141 Failure Code [DA7AMC]......................................................................................................2147 Failure Code [DA7BKK]......................................................................................................2148 Failure Code [DA7CKP]......................................................................................................2150 Failure Code [DA7DKP]......................................................................................................2153 Failure Code [DA7EKQ]......................................................................................................2156 Failure Code [DA7FKA]......................................................................................................2158 Failure Code [DA7FKB]......................................................................................................2160 Failure Code [DA7GKR]......................................................................................................2162 Failure Code [DA7HKR]......................................................................................................2171 Failure Code [DA7JKR]......................................................................................................2177 Failure Code [DAF0KM]......................................................................................................2182 Failure Code [DAF0KT]......................................................................................................2183 Failure Code [DAF0MB]......................................................................................................2184 Failure Code [DAF0MC]......................................................................................................2185 Failure Code [DAF3KK]......................................................................................................2186 Failure Code [DAF8KB]......................................................................................................2189 Failure Code [DAF9KQ]......................................................................................................2191 Failure Code [DAFGMC]......................................................................................................2192 Failure Code [DAFLKA]......................................................................................................2193 Failure Code [DAFLKB]......................................................................................................2195 Failure Code [DAFQKR]......................................................................................................2197 Failure Code [DAZ9KQ]......................................................................................................2205 Failure Code [DAZQKR]......................................................................................................2206 Failure Code [DB2QKR]......................................................................................................2213 Failure Code [DB2RKR]......................................................................................................2222 Failure Code [DBP0KM]......................................................................................................2228 Failure Code [DBP0KT]......................................................................................................2229 Failure Code [DBP5KB]......................................................................................................2230 Failure Code [DBP5KY]......................................................................................................2233 Failure Code [DBPQKR]......................................................................................................2236 Failure Code [DBZ0MC]......................................................................................................2244 Failure Code [DBZ2KK]......................................................................................................2245 Failure Code [DBZ2KT]......................................................................................................2247 Failure Code [DBZ5KP]......................................................................................................2248 Failure Code [DBZ6KP]......................................................................................................2250 Failure Code [DBZ6KP] (Counterweight remover specifications)...............................................................2252 Failure Code [DBZ9KQ]......................................................................................................2254 Failure Code [DBZLKA]......................................................................................................2256 Failure Code [DBZLKB]......................................................................................................2258 Failure Code [DBZQKR]......................................................................................................2260 Failure Code [DBZRKR]......................................................................................................2269 Failure Code [DDNRKA]......................................................................................................2274 Failure Code [DDNRKY]......................................................................................................2276 Failure Code [DDNS00]......................................................................................................2278 Failure Code [DGE5KB]......................................................................................................2280 Failure Code [DGH2KA]......................................................................................................2282 Failure Code [DGH2KB]......................................................................................................2284 Failure Code [DH25MA]......................................................................................................2286 Failure Code [DH26MA]......................................................................................................2288 Failure Code [DHA4KA]......................................................................................................2290 Failure Code [DHAAMA]......................................................................................................2292 Failure Code [DHACMA]......................................................................................................2294 Failure Code [DHF1MA]......................................................................................................2296 Failure Code [DHF2MA]......................................................................................................2298 Failure Code [DHF7L8]......................................................................................................2300 Failure Code [DHF7MA]......................................................................................................2302 Failure Code [DHF8L8]......................................................................................................2304 Failure Code [DHF8MA]......................................................................................................2306 Failure Code [DHHDMA]......................................................................................................2308 Failure Code [DHHDZG]......................................................................................................2310 Failure Code [DHHEMA]......................................................................................................2311 Failure Code [DHHFMA]......................................................................................................2313 Failure Code [DHPEMA]......................................................................................................2315 Failure Code [DHPFMA]......................................................................................................2317 Failure Code [DHPTMA]......................................................................................................2319 Failure Code [DHPUMA]......................................................................................................2321 Failure Code [DHS3MA]......................................................................................................2323 Failure Code [DHS4MA]......................................................................................................2326 Failure Code [DHS8MA]......................................................................................................2328 Failure Code [DHS9MA]......................................................................................................2331 Failure Code [DHSAMA]......................................................................................................2334 Failure Code [DHSBMA]......................................................................................................2336 Failure Code [DHSCMA]......................................................................................................2339 Failure Code [DHSDMA]......................................................................................................2341 Failure Code [DHSFMA]......................................................................................................2344 Failure Code [DHSGMA]......................................................................................................2346 Failure Code [DHSHMA]......................................................................................................2349 Failure Code [DHSJMA]......................................................................................................2352 Failure Code [DHSVMA]......................................................................................................2355 Failure Code [DHVAL8]......................................................................................................2357 Failure Code [DHVAMA]......................................................................................................2359 Failure Code [DHVBL8]......................................................................................................2361 Failure Code [DHVBMA]......................................................................................................2363 Failure Code [DJS1MA]......................................................................................................2365 Failure Code [DKK0KB]......................................................................................................2367 Failure Code [DKK0MA]......................................................................................................2369 Failure Code [DKR0MA]......................................................................................................2371 Failure Code [DKR1MA]......................................................................................................2373 Failure Code [DKR2MA]......................................................................................................2375 Failure Code [DKR2NX]......................................................................................................2378 Failure Code [DKR3MA]......................................................................................................2380 Failure Code [DKR3NX]......................................................................................................2383 Failure Code [DKR5MA]......................................................................................................2385 Failure Code [DKR6MA]......................................................................................................2388 Failure Code [DKTKMA]......................................................................................................2391 Failure Code [DKTMMA]......................................................................................................2393 Failure Code [DKTNMA]......................................................................................................2395 Failure Code [DKTPMA]......................................................................................................2397 Failure Code [DKULKA]......................................................................................................2399 Failure Code [DKULKB]......................................................................................................2401 Failure Code [DKULKY]......................................................................................................2403 Failure Code [DKV5L8]......................................................................................................2405 Failure Code [DKV5MA]......................................................................................................2407 Failure Code [DKVEL8]......................................................................................................2409 Failure Code [DKVEMA]......................................................................................................2411 Failure Code [DKVFL8]......................................................................................................2413 Failure Code [DKVFMA]......................................................................................................2415 Failure Code [DKVGL8]......................................................................................................2417 Failure Code [DKVGMA]......................................................................................................2419 Failure Code [DKVHL8]......................................................................................................2421 Failure Code [DKVHMA]......................................................................................................2423 Failure Code [DKVJL8]......................................................................................................2425 Failure Code [DKVJMA]......................................................................................................2427 Failure Code [DLM3KA]......................................................................................................2429 Failure Code [DLM3KB]......................................................................................................2431 Failure Code [DLM3MB]......................................................................................................2433 Failure Code [DLM8KA]......................................................................................................2434 Failure Code [DLM8KB]......................................................................................................2435 Failure Code [DLM8MB]......................................................................................................2436 Failure Code [DLMCLC]......................................................................................................2437 Failure Code [DLMCMA]......................................................................................................2439 Failure Code [DR10KA]......................................................................................................2440 Failure Code [DR12KA]......................................................................................................2443 Failure Code [DR20KA]......................................................................................................2445 Failure Code [DR21KX]......................................................................................................2447 Failure Code [DR30KA]......................................................................................................2449 Failure Code [DR31KX]......................................................................................................2451 Failure Code [DR40KA]......................................................................................................2453 Failure Code [DUMBKA]......................................................................................................2455 Failure Code [DUMBKB]......................................................................................................2457 Failure Code [DV20KB]......................................................................................................2459 Failure Code [DW43KA]......................................................................................................2461 Failure Code [DW43KB]......................................................................................................2463 Failure Code [DW43KY]......................................................................................................2465 Failure Code [DW45KA]......................................................................................................2466 Failure Code [DW45KB]......................................................................................................2469 Failure Code [DW45KY]......................................................................................................2472 Failure Code [DW4CKY]......................................................................................................2474 Failure Code [DW7BKA]......................................................................................................2476 Failure Code [DW7BKB]......................................................................................................2478 Failure Code [DW7BKY]......................................................................................................2480 Failure Code [DW7HKA]......................................................................................................2481 Failure Code [DW7HKB]......................................................................................................2482 Failure Code [DW7HKY]......................................................................................................2483 Failure Code [DW91KA]......................................................................................................2484 Failure Code [DW91KB]......................................................................................................2485 Failure Code [DW91KY]......................................................................................................2486 Failure Code [DWK2KA]......................................................................................................2487 Failure Code [DWK2KB]......................................................................................................2489 Failure Code [DWK2KY]......................................................................................................2491 Failure Code [DWM1KA]......................................................................................................2492 Failure Code [DWM1KB]......................................................................................................2493 Failure Code [DWM1KY]......................................................................................................2494 Failure Code [DWN5KA]......................................................................................................2495 Failure Code [DWN5KB]......................................................................................................2496 Failure Code [DWNCKA]......................................................................................................2497 Failure Code [DWNCKB]......................................................................................................2498 Failure Code [DXAAKA]......................................................................................................2499 Failure Code [DXAAKA] (Counterweight Remover Specifications)...............................................................2501 Failure Code [DXAAKB]......................................................................................................2504 Failure Code [DXAAKB] (Counterweight Remover Specifications)...............................................................2506 Failure Code [DXABKA]......................................................................................................2508 Failure Code [DXABKB]......................................................................................................2510 Failure Code [DXACKA]......................................................................................................2512 Failure Code [DXACKB]......................................................................................................2514 Failure Code [DXACKY]......................................................................................................2516 Failure Code [DXACL8]......................................................................................................2518 Failure Code [DXADKA]......................................................................................................2519 Failure Code [DXADKB]......................................................................................................2521 Failure Code [DXADKY]......................................................................................................2523 Failure Code [DXADL8]......................................................................................................2525 Failure Code [DXAEKA]......................................................................................................2526 Failure Code [DXAEKB]......................................................................................................2528 Failure Code [DXAEKY]......................................................................................................2530 Failure Code [DXAEL8]......................................................................................................2532 Failure Code [DXAFKA]......................................................................................................2533 Failure Code [DXAFKB]......................................................................................................2535 Failure Code [DXAFKY]......................................................................................................2537 Failure Code [DXAFL8]......................................................................................................2539 Failure Code [DXAGKA]......................................................................................................2540 Failure Code [DXAGKB]......................................................................................................2541 Failure Code [DXP1KA]......................................................................................................2542 Failure Code [DXP1KB]......................................................................................................2544 Failure Code [DXP1KY]......................................................................................................2546 Failure Code [DXP1L8]......................................................................................................2548 Failure Code [DXP2KA]......................................................................................................2549 Failure Code [DXP2KB]......................................................................................................2551 Failure Code [DXP2KY]......................................................................................................2553 Failure Code [DXP2L8]......................................................................................................2555 Failure Code [DXR3KA]......................................................................................................2556 Failure Code [DXR3KB]......................................................................................................2557 Failure Code [DXR3KY]......................................................................................................2558 Failure Code [DXR4KA]......................................................................................................2559 Failure Code [DXR4KB]......................................................................................................2560 Failure Code [DXR4KY]......................................................................................................2561 Failure Code [DXR6KA]......................................................................................................2562 Failure Code [DXR6KB]......................................................................................................2563 Failure Code [DXR6KY]......................................................................................................2564 Failure Code [DXR9KA]......................................................................................................2565 Failure Code [DXR9KB]......................................................................................................2566 Failure Code [DXR9KY]......................................................................................................2567 Failure Code [DXRCKA]......................................................................................................2568 Failure Code [DXRCKB]......................................................................................................2569 Failure Code [DXRCKY]......................................................................................................2570 Failure Code [DXRFKA]......................................................................................................2571 Failure Code [DXRFKB]......................................................................................................2572 Failure Code [DXRFKY]......................................................................................................2573 Failure Code [DXRGKA]......................................................................................................2574 Failure Code [DXRGKB]......................................................................................................2575 Failure Code [DXRGKY]......................................................................................................2576 Failure Code [DXRJKA]......................................................................................................2577 Failure Code [DXRJKB]......................................................................................................2578 Failure Code [DXRJKY]......................................................................................................2579 Failure Code [DXRKKA]......................................................................................................2580 Failure Code [DXRKKB]......................................................................................................2581 Failure Code [DXRKKY]......................................................................................................2582 Failure Code [DY20KA]......................................................................................................2583 Failure Code [DY20MA]......................................................................................................2585 Failure Code [DY2CKA]......................................................................................................2587 Failure Code [DY2CKB]......................................................................................................2589 Failure Code [DY2DKB]......................................................................................................2591 Failure Code [DY2EKB]......................................................................................................2593 Failure Code [DY2FMA]......................................................................................................2595 Failure Code [DY2GKM]......................................................................................................2597 Failure Code [F311KA]......................................................................................................2599 Failure Code [F311KB]......................................................................................................2601 Failure Code [F312KA]......................................................................................................2603 Failure Code [F312KB]......................................................................................................2605 Failure Code [F313KA]......................................................................................................2607 Failure Code [F313KB]......................................................................................................2609 Failure Code [F314KA]......................................................................................................2612 Failure Code [F314KB]......................................................................................................2614 Failure Code [F315KB]......................................................................................................2616 Failure Code [F315KY]......................................................................................................2618 Failure Code [F316KB]......................................................................................................2620 Failure Code [F316KY]......................................................................................................2622 Failure Code [F318KB]......................................................................................................2624 Failure Code [F318KY]......................................................................................................2627 Failure Code [F31AKB]......................................................................................................2629 Failure Code [F31AKY]......................................................................................................2631 Failure Code [F31BKB]......................................................................................................2633 Failure Code [F31BKY]......................................................................................................2635 Failure Code [F31CKB]......................................................................................................2637 Failure Code [F31CKY]......................................................................................................2639 Failure Code [F31DKB]......................................................................................................2641 Failure Code [F31DKY]......................................................................................................2643 Failure Code [F31EKB]......................................................................................................2645 Failure Code [F31EKY]......................................................................................................2647 Failure Code [LA10ZL]......................................................................................................2649 Failure Code [LA20ZL]......................................................................................................2650 Troubleshooting of Electrical System (E-Mode)..................................................................................2651 Engine Does Not Start (Engine Does Not Crank)..............................................................................2651 Manual Preheating System Does Not Operate..................................................................................2657 Automatic Preheating System Does Not Operate...............................................................................2660 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................2662 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................2664 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow..........2667 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....2668 Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation..........................................2669 Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation...........................................2670 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation...............................................2671 Charge Level Monitor Comes On in Red While Engine is in Operation..........................................................2672 Fuel Level Monitor Comes On in Red While Engine is in Operation............................................................2673 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation............................................2674 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation...................................................2675 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation.............................................2676 Fuel Gauge Does Not Move from Minimum or Maximum...........................................................................2677 Display of Fuel Gauge is Different from Actual Fuel Level..................................................................2679 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum....................................................2680 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..........................................2681 Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum......................................................2682 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature........................................2684 Some Areas of Machine Monitor Screen are Not Shown.........................................................................2685 Function Switch Does Not Operate...........................................................................................2686 Automatic Warm-up System Does Not Operate (in Cold Weather)................................................................2687 Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated............................2688 Auto-Decelerator is Not Operated or Canceled with Lever....................................................................2689 Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated..................................................2690 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed..........................................2691 Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated.................................................2692 Travel Speed Does Not Change Even When You Change Travel Speed.............................................................2693 Alarm Buzzer Does Not Stop.................................................................................................2694 Service Meter is Not Shown While Starting Switch is in OFF Position........................................................2695 Service Mode Cannot be Selected............................................................................................2696 All Work Equipment, Swing, Travel Do Not Operate...........................................................................2697 All Work Equipment, Swing and Travel Do Not Operate (Counterweight remover specification)..................................2700 All Work Equipment, Swing, Travel Cannot be Locked.........................................................................2703 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock (Counterweight remover specification).......................2705 Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position.................................2707 While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated.........................................2710 Travel Alarm Does Not Operate During Travel................................................................................2712 Travel Alarm Does Not Stop When Machine Stops..............................................................................2714 Horn Does Not Sound........................................................................................................2715 Horn Does Not Stop.........................................................................................................2718 Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated....................................................2720 Windshield Wiper Does Not Operate When Wiper Switch is Operated............................................................2721 When Window Washer Switch is Operated, Window Washer Does Not Operate......................................................2723 Fuel Feed Pump Does Not Operate or Stop Automatically......................................................................2724 "Boom RAISE" is Not Shown Correctly with Monitoring Function...............................................................2727 "Boom LOWER" is Not Shown Correctly with Monitoring Function...............................................................2728 "Arm OUT" is Not Shown Correctly with Monitoring Function..................................................................2729 "Arm IN" is Not Shown Correctly with Monitoring Function...................................................................2730 Bucket DUMP is Not Shown Correctly with Monitoring Function................................................................2731 Bucket CURL is Not Shown Correctly with Monitoring Function................................................................2732 Swing is Not Shown Correctly with Monitoring Function......................................................................2733 "Right Travel" is Not Shown Correctly with Monitoring Function.............................................................2734 "Left Travel" is Not Shown Correctly with Monitoring Function..............................................................2735 KOMTRAX System Does Not Operate Correctly..................................................................................2736 Machine Push-up Function Cannot be Canceled................................................................................2737 Machine Push-up Function Does Not Operate..................................................................................2739 Step Light Does Not Come on................................................................................................2740 Step Light Does Not Go out.................................................................................................2742 Boom Shockless Function Cannot be Canceled.................................................................................2744 Boom Shockless Function Does Not Work......................................................................................2746 Electric Grease Gun Does Not Work..........................................................................................2748 Electric Grease Gun Does Not Stop..........................................................................................2750 Screen Shows that Emergency Stop Button is Operated........................................................................2752 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)..................................................................2754 All Work Equipment or Travel Does Not Operate..............................................................................2754 All Work Equipment and Travel Speeds are Low or Power is Low...............................................................2755 Engine Speed Drops Largely or Engine Stops.................................................................................2757 Unusual Noise is Heard from Around Work Equipment Pump and Swing Pump......................................................2758 Boom RAISE Speed or Power is Low...........................................................................................2759 Boom LOWER Speed or Power is Low...........................................................................................2760 Boom LOWER Speed or Power is Low in Machine Push Up Mode...................................................................2762 Arm Speed or Power is Low..................................................................................................2763 Bucket Speed or Power is Low...............................................................................................2764 Boom Does Not Operate......................................................................................................2765 Arm Does Not Operate.......................................................................................................2766 Bucket Does Not Operate....................................................................................................2767 Hydraulic Drift of Boom is Large...........................................................................................2768 Hydraulic Drift of Arm is Large............................................................................................2769 Hydraulic Drift of Bucket is Large.........................................................................................2770 Time Lag of Boom is Large..................................................................................................2771 Time Lag of Arm is Large...................................................................................................2772 Time Lag of Bucket is Large................................................................................................2773 Machine Unintentionally Turns to One Side When Machine Travels.............................................................2774 Travel Deviation is Large at Start of Travel Only When Travel Lever is Fully Moved.........................................2775 Regardless of the Stroke of the Travel Lever, Travel Deviation is Large at Start of Traveling..............................2776 Travel Deviation is Large at Mixed Operation...............................................................................2777 Travel Speed or Power is Low...............................................................................................2778 Only the One Side Track Can Operate (Machine Does Not Travel Forward or Reverse)...........................................2779 Only the One Side Track Can Operate (Machine Can Travel Only Forward or Reverse)...........................................2780 Travel Speed Does Not Change...............................................................................................2781 Upper Structure Does Not Swing in Two Directions of Right and Left.........................................................2782 Machine Swings Only in One Direction.......................................................................................2784 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left)............................................2786 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction..............................2788 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)...........................................2790 Upper Structure Speed is High When It Stops Swing Operation (on One Side)..................................................2791 Shock is Large When Upper Structure Stops Swing Operation (Right and Left).................................................2793 Shock is Large When Upper Structure Starts and Stops Swing Operation.......................................................2794 Unusual Noise is Heard from Around Swing Pump or Motor.....................................................................2795 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation in Only One Direction..............................2796 Swing Drift of Swing is Large..............................................................................................2797 Fan Rotation is Abnormal (Such as Excessive Noise or Vibration of Fan, or Overheating).....................................2798 Troubleshooting of Engine (S-Mode).............................................................................................2799 Information Shown in Troubleshooting Table (S-Mode)........................................................................2799 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position.................................................2800 S-2 Engine Cranks but No Exhaust Smoke Comes Out...........................................................................2801 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...............................2802 S-4 Engine Startability is Unsatisfactory..................................................................................2803 S-5 Engine Does Not Pick Up Smoothly.......................................................................................2805 S-6 Engine Stops During Operation..........................................................................................2807 S-7 Engine Runs Rough or is Not Stable.....................................................................................2809 S-8 Engine Lacks Power.....................................................................................................2810 S-9 KDPF Becomes Clogged in a Short Time...................................................................................2812 S-10 Engine Oil Consumption is Excessive...................................................................................2814 S-11 Oil Becomes Dirty Quickly.............................................................................................2815 S-12 Fuel Consumption is Excessive.........................................................................................2816 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant..................................................................2817 S-14 Oil Pressure Drops....................................................................................................2818 S-15 Fuel Mixes Into Engine Oil............................................................................................2820 S-16 Water Mixes Into Engine Oil (Milky)...................................................................................2821 S-17 Coolant Temperature Increases Too High (Overheating)..................................................................2822 S-18 Unusual Noise is Heard................................................................................................2823 S-19 Vibration is Excessive................................................................................................2824 S-20 Air Cannot be Bled from Fuel Circuit..................................................................................2825 S-21 Active Regeneration is Done Frequently................................................................................2826 S-22 Active Regeneration Continues Long....................................................................................2830 S-23 White Smoke is Exhausted During Active Regeneration...................................................................2831 S-24 DEF Consumption is Excessive..........................................................................................2832 S-25 There is Unusual Smell (Irritating Odor)..............................................................................2834 S-26 Foreign Materials Enter DEF (DEF Increases)...........................................................................2835 50 Disassembly and Assembly........................................................................................................2837 Table of Contents..............................................................................................................2838 Precautions Before Work........................................................................................................2845 Related Information on Disassembly and Assembly................................................................................2846 How to Read This Manual....................................................................................................2846 Coating Materials List.....................................................................................................2848 Special Tool List..........................................................................................................2853 Sketches of Special Tools..................................................................................................2878 Prepare........................................................................................................................2888 Drain and Add Coolant......................................................................................................2888 How to Drain Coolant...................................................................................................2888 How to Add Coolant.....................................................................................................2889 Drain and Add Hydraulic Oil................................................................................................2890 How to Drain Hydraulic Oil.............................................................................................2890 How to Add Hydraulic Oil...............................................................................................2891 Drain and Add Fuel.........................................................................................................2892 How to Drain Fuel......................................................................................................2892 How to Add Fuel........................................................................................................2892 Collect and Refill Refrigerant.............................................................................................2893 How to Collect Refrigerant.............................................................................................2893 How to Refill Refrigerant..............................................................................................2894 Engine and Cooling System......................................................................................................2895 Remove and Install Supply Pump Assembly....................................................................................2895 How to Remove Supply Pump Assembly.....................................................................................2895 How to Install Supply Pump Assembly....................................................................................2896 Remove and Install Injector Assembly.......................................................................................2900 How to Remove Injector Assembly........................................................................................2900 How to Install Injector Assembly.......................................................................................2909 Remove and Install Fuel Doser Assembly.....................................................................................2921 How to Remove Fuel Doser Assembly......................................................................................2921 How to Install Fuel Doser Assembly.....................................................................................2922 Remove and Install Cylinder Head Assembly..................................................................................2924 How to Remove Cylinder Head Assembly...................................................................................2924 How to Install Cylinder Head Assembly..................................................................................2935 Remove and Install EGR Valve Assembly......................................................................................2953 How to Remove EGR Valve Assembly.......................................................................................2953 How to Install EGR Valve Assembly......................................................................................2955 Remove and Install EGR Cooler Assembly.....................................................................................2957 How to Remove EGR Cooler Assembly......................................................................................2957 Install EGR Cooler Assembly............................................................................................2959 Remove and Install Starter Assembly........................................................................................2963 How to Remove Starting Motor Assembly..................................................................................2963 How to Install Starting Motor Assembly.................................................................................2963 Remove and Install Alternator Belt.........................................................................................2965 How to Remove Alternator Belt..........................................................................................2965 How to Install Alternator Belt.........................................................................................2966 Remove and Install Radiator Assembly.......................................................................................2968 How to Remove Radiator Assembly........................................................................................2968 How to Install Radiator Assembly.......................................................................................2971 Remove and Install Hydraulic Oil Cooler Assembly...........................................................................2976 How to Remove Hydraulic Oil Cooler Assembly............................................................................2976 How to Install Hydraulic Oil Cooler Assembly...........................................................................2982 Remove and Install Aftercooler Assembly....................................................................................2989 How to Remove Aftercooler Assembly.....................................................................................2989 How to Install Aftercooler Assembly....................................................................................2992 Remove and Install Cooler Assembly.........................................................................................2996 How to Remove Cooling Assembly.........................................................................................2996 How to Install Cooling Assembly........................................................................................3009 Remove and Install Cooling Fan Motor Assembly..............................................................................3023 How to Remove Cooling Fan Motor Assembly...............................................................................3023 How to Install Cooling Fan Motor Assembly..............................................................................3042 Remove and Install Engine, PTO, and Hydraulic Pump Assembly................................................................3063 How to Remove Engine, PTO, and Hydraulic Pump Assembly.................................................................3064 How to Install Engine, PTO, and Hydraulic Pump Assembly................................................................3087 Remove and Install Engine Front Oil Seal...................................................................................3110 How to Remove Engine Front Oil Seal....................................................................................3110 How to Install Engine Front Oil Seal...................................................................................3111 Remove and Install Engine Rear Oil Seal....................................................................................3114 How to Remove Engine Rear Oil Seal.....................................................................................3114 How to Install Engine Rear Oil Seal....................................................................................3116 Remove and Install Engine Hood Assembly....................................................................................3122 How to Remove Engine Hood Assembly.....................................................................................3122 How to Install Engine Hood Assembly....................................................................................3126 Remove and Install Fuel Tank Assembly......................................................................................3132 How to Remove Fuel Tank Assembly.......................................................................................3132 How to Install Fuel Tank Assembly......................................................................................3136 Remove and Install DEF Tank Assembly.......................................................................................3141 How to Remove DEF Tank Assembly........................................................................................3141 How to Install DEF Tank Assembly.......................................................................................3153 Remove and Install DEF Tank Sensor Flange Assembly.........................................................................3165 How to Remove DEF Tank Sensor Flange Assembly..........................................................................3165 How to Install DEF Tank Sensor Flange Assembly.........................................................................3166 Remove and Install DEF Tank Sensor.........................................................................................3168 How to Remove DEF Tank Sensor..........................................................................................3168 How to Install DEF Tank Sensor.........................................................................................3169 Remove and Install DEF Tank Strainer.......................................................................................3175 How to Remove DEF Tank Strainer........................................................................................3175 How to Install DEF Tank Strainer.......................................................................................3175 Remove and Install DEF Tank Filler Port Filter.............................................................................3176 How to Remove DEF Tank Filler Port Filter..............................................................................3176 How to Install DEF Tank Filler Port Filter.............................................................................3179 Remove and Install KDPF Assembly...........................................................................................3184 How to Remove KDPF Assembly............................................................................................3184 How to Install KDPF Assembly...........................................................................................3187 Disassemble and Assemble KDPF Assembly.....................................................................................3190 How to Disassemble KDPF Assembly.......................................................................................3190 How to Assemble KDPF Assembly..........................................................................................3194 Remove and Install SCR Assembly............................................................................................3199 How to Remove SCR Assembly.............................................................................................3199 How to Install SCR Assembly............................................................................................3201 Remove and Install KDPF and SCR Assembly...................................................................................3204 How to Remove KDPF and SCR Assembly....................................................................................3205 How to Install KDPF and SCR Assembly...................................................................................3210 Remove and Install Bellows Pipe Assembly...................................................................................3216 How to Remove Bellows Pipe Assembly....................................................................................3216 How to Install Bellows Pipe Assembly...................................................................................3218 Remove and Install KCCV Assembly...........................................................................................3220 How to Remove KCCV Assembly............................................................................................3220 How to Install KCCV Assembly...........................................................................................3222 Remove and Install DEF Mixing Tube.........................................................................................3225 How to Remove DEF Mixing Tube..........................................................................................3225 How to Install DEF Mixing Tube.........................................................................................3231 Remove and Install DEF Injector............................................................................................3238 How to Remove DEF Injector.............................................................................................3238 How to Install DEF Injector............................................................................................3241 Remove and Install DEF Pump................................................................................................3244 How to Remove DEF Pump.................................................................................................3244 How to Install DEF Pump................................................................................................3247 Remove and Install DEF Hose................................................................................................3250 How to Remove DEF Hose.................................................................................................3250 How to Install DEF Hose................................................................................................3264 Remove and Install Air Cleaner Assembly....................................................................................3279 How to Remove Air Cleaner Assembly.....................................................................................3279 How to Install Air Cleaner Assembly....................................................................................3282 Remove and Install Air Conditioner Compressor Assembly.....................................................................3285 How to Remove Air Conditioner Compressor Assembly......................................................................3285 How to Install Air Conditioner Compressor Assembly.....................................................................3286 Remove and Install Air Conditioner Condenser Assembly......................................................................3288 How to Remove Air Conditioner Condenser Assembly.......................................................................3288 How to Install Air Conditioner Condenser Assembly......................................................................3289 Power Train....................................................................................................................3291 Remove and Install PTO Assembly............................................................................................3291 How to Remove PTO Assembly.............................................................................................3291 How to Install PTO Assembly............................................................................................3297 Disassemble and Assemble PTO Assembly......................................................................................3303 How to Disassemble PTO Assembly........................................................................................3303 How to Assemble PTO Assembly...........................................................................................3306 Remove and Install Travel Motor and Final Drive Assembly...................................................................3310 How to Remove Travel Motor and Final Drive Assembly....................................................................3310 How to Install Travel Motor and Final Drive Assembly...................................................................3311 Disassemble and Assemble Final Drive Assembly (PC900LC-11).................................................................3313 How to Disassemble Final Drive Assembly (PC900LC-11)...................................................................3314 How to Assemble Final Drive Assembly (PC900LC-11)......................................................................3318 Disassemble and Assemble Final Drive Assembly (PC950-11E0, PC950LC-11E0)...................................................3328 How to Disassemble Final Drive Assembly (PC950-11E0, PC950LC-11E0).....................................................3329 How to Assemble Final Drive Assembly (PC950-11E0, PC950LC-11E0)........................................................3333 Remove and Install Swing Motor and Swing Machinery Assembly................................................................3343 How to Remove Swing Motor and Swing Machinery Assembly.................................................................3343 How to Install Swing Motor and Swing Machinery Assembly................................................................3350 Disassemble and Assemble Swing Machinery Assembly..........................................................................3357 How to Disassemble Swing Machinery Assembly............................................................................3357 How to Assemble Swing Machinery Assembly...............................................................................3361 Remove and Install Swing Circle Assembly...................................................................................3367 How to Remove Swing Circle Assembly....................................................................................3367 How to Install Swing Circle Assembly...................................................................................3368 Undercarriage and Frame........................................................................................................3369 Disassemble and Assemble One Track Link Assembly in Field..................................................................3369 Disassemble One Track Link Assembly in Field...........................................................................3370 Assemble One Track Link Assembly in Field..............................................................................3371 Separate and Connect Track Assembly........................................................................................3373 Separate Track Assembly................................................................................................3373 How to Install Track Assembly..........................................................................................3374 Remove and Install Idler Assembly..........................................................................................3376 How to Remove Idler Assembly...........................................................................................3376 How to Install Idler Assembly..........................................................................................3377 Remove and Install Idler Cushion Assembly..................................................................................3379 How to Remove Idler Cushion Assembly...................................................................................3379 How to Install Idler Cushion Assembly..................................................................................3379 Disassemble and Assemble Idler Assembly (PC900LC-11).......................................................................3381 How to Disassemble Idler Assembly (PC900LC-11).........................................................................3381 How to Assemble Idler Assembly (PC900LC-11)............................................................................3382 Disassemble and Assemble Idler Assembly (PC950-11E0, PC950LC-11E0).........................................................3385 How to Disassemble Idler Assembly (PC950-11E0, PC950LC-11E0)...........................................................3385 How to Assemble Idler Assembly (PC950-11E0, PC950LC-11E0)..............................................................3386 Disassemble and Assemble Idler Cushion Assembly............................................................................3389 How to Disassemble Idler Cushion Assembly..............................................................................3389 Assemble Idler Cushion Assembly........................................................................................3390 Remove and Install Track Roller Assembly (PC900LC-11)......................................................................3392 How to Remove Track Roller Assembly (PC900LC-11).......................................................................3392 How to Install Track Roller Assembly (PC900LC-11)......................................................................3393 Remove and Install Track Roller Assembly (PC950-11E0, PC950LC-11E0)........................................................3395 How to Remove Track Roller Assembly (PC950-11E0, PC950LC-11E0).........................................................3395 How to Install Track Roller Assembly (PC950-11E0, PC950LC-11E0)........................................................3397 Remove and Install Carrier Roller Assembly.................................................................................3399 How to Remove Carrier Roller Assembly..................................................................................3399 How to Install Carrier Roller Assembly.................................................................................3400 Disassemble and Assemble Track Roller Assembly (PC900LC-11)................................................................3401 How to Disassemble Track Roller Assembly (PC900LC-11)..................................................................3401 How to Assemble Track Roller Assembly (PC900LC-11).....................................................................3402 Disassemble and Assemble Track Roller Assembly (PC950-11E0, PC950LC-11E0)..................................................3405 How to Disassemble Track Roller Assembly (PC950-11E0, PC950LC-11E0)....................................................3405 How to Assemble Track Roller Assembly (PC950-11E0, PC950LC-11E0).......................................................3406 Disassemble and Assemble Carrier Roller Assembly (PC900LC-11)..............................................................3409 Disassemble Carrier Roller Assembly (PC900LC-11).......................................................................3409 How to Assemble Carrier Roller Assembly (PC900LC-11)...................................................................3410 Disassemble and Assemble Carrier Roller Assembly (PC950-11E0, PC950LC-11E0)................................................3412 How to Disassemble Carrier Roller Assembly (PC950-11E0, PC950LC-11E0)..................................................3412 How to Assemble Carrier Roller Assembly (PC950-11E0, PC950LC-11E0).....................................................3413 Remove and Install Revolving Frame Assembly................................................................................3415 How to Remove Revolving Frame Assembly.................................................................................3415 How to Install Revolving Frame Assembly................................................................................3418 Remove and Install Counterweight Assembly..................................................................................3422 How to Remove Counterweight Assembly...................................................................................3422 How to Install Counterweight Assembly..................................................................................3424 Remove and Install Counterweight Remove Cylinder Assembly..................................................................3425 How to Remove Counterweight Remover Cylinder Assembly..................................................................3425 How to Install Counterweight Remover Cylinder Assembly.................................................................3429 Hydraulic System...............................................................................................................3434 Remove and Install Center Swivel Joint Assembly............................................................................3434 How to Remove Center Swivel Joint Assembly.............................................................................3434 Install Center Swivel Joint Assembly...................................................................................3437 Disassemble and Assemble Center Swivel Joint Assembly......................................................................3440 How to Disassemble Center Swivel Joint Assembly........................................................................3440 How to Assemble Center Swivel Joint Assembly...........................................................................3441 Remove and Install Hydraulic Tank Assembly.................................................................................3442 How to Remove Hydraulic Tank Assembly..................................................................................3442 How to Install Hydraulic Tank Assembly.................................................................................3451 Remove and Install Hydraulic Pump Assembly.................................................................................3461 How to Remove Hydraulic Pump Assembly..................................................................................3461 How to Install Hydraulic Pump Assembly.................................................................................3475 Remove and Install Control Valve Assembly..................................................................................3489 How to Remove Control Valve Assembly...................................................................................3489 How to Install Control Valve Assembly..................................................................................3498 Remove and Install Neutral Hold Valve Assembly.............................................................................3506 How to Remove Neutral Hold Valve Assembly..............................................................................3506 How to Install Neutral Assembly........................................................................................3511 Remove and Install Swing Motor Assembly....................................................................................3517 How to Remove Swing Motor Assembly.....................................................................................3517 How to Install Swing Motor Assembly....................................................................................3523 Disassemble and Assemble Work Equipment PPC Valve Assembly.................................................................3530 How to Disassemble Work Equipment PPC Valve Assembly...................................................................3530 How to Assemble Work Equipment PPC Valve Assembly......................................................................3531 Disassemble and Assemble Travel PPC Valve Assembly.........................................................................3533 How to Disassemble Travel PPC Valve Assembly...........................................................................3533 How to Assemble Travel PPC Valve Assembly..............................................................................3534 Disassemble and Assemble Grease Gun Assembly...............................................................................3536 How to Disassemble Grease Gun Assembly.................................................................................3536 How to Assemble Grease Gun Assembly....................................................................................3536 Work Equipment.................................................................................................................3537 Remove and Install Boom Anti-drop Valve Assembly...........................................................................3537 How to Remove Boom Anti-drop Valve Assembly............................................................................3537 How to Install Boom Anti-drop Valve Assembly...........................................................................3539 Remove and Install Arm Anti-Drop Valve Assembly............................................................................3540 How to Remove Arm Anti-Drop Valve Assembly.............................................................................3540 How to Install Arm Anti-Drop Valve Assembly............................................................................3542 Disassemble and Assemble Arm Anti-Drop Valve Assembly......................................................................3543 How to Disassemble Arm Anti-drop Valve Assembly........................................................................3543 How to Assemble Arm Anti-drop Valve Assembly...........................................................................3543 Remove and Install Bucket Cylinder Assembly................................................................................3544 How to Remove Bucket Cylinder Assembly.................................................................................3544 How to Install Bucket Cylinder Assembly................................................................................3545 Remove and Install Arm Cylinder Assembly...................................................................................3547 How to Remove Arm Cylinder Assembly....................................................................................3547 How to Install Arm Cylinder Assembly...................................................................................3550 Remove and Install Boom Cylinder Assembly..................................................................................3553 How to Remove Boom Cylinder Assembly...................................................................................3553 How to Install Boom Cylinder Assembly..................................................................................3556 Remove and Install Bucket Assembly.........................................................................................3560 How to Remove Bucket Assembly..........................................................................................3561 How to Install Bucket Assembly.........................................................................................3562 Remove and Install Arm Assembly............................................................................................3564 How to Remove Arm Assembly.............................................................................................3564 How to Install Arm Assembly............................................................................................3565 Remove and Install Boom Assembly...........................................................................................3567 How to Remove Boom Assembly............................................................................................3567 How to Install Boom Assembly...........................................................................................3569 Disassemble and Assemble Counterweight Remover Cylinder Assembly...........................................................3572 How to Disassemble and Assemble Counterweight Remover Cylinder Assembly................................................3572 How to Assemble Counterweight Remover Cylinder Assembly................................................................3574 Disassemble and Assemble Boom Cylinder Assembly............................................................................3579 How to Disassemble Boom Cylinder Assembly..............................................................................3579 How to Assemble Boom Cylinder Assembly.................................................................................3581 Disassemble and Assemble Bucket Cylinder Assembly..........................................................................3586 How to Disassemble Bucket Cylinder Assembly............................................................................3586 How to Assemble Bucket Cylinder Assembly...............................................................................3588 Disassemble and Assemble Arm Cylinder Assembly.............................................................................3594 How to Disassemble Arm Cylinder Assembly...............................................................................3594 How to Assemble Arm Cylinder Assembly..................................................................................3597 CAB Related Parts..............................................................................................................3601 Remove and Install Operator Cab Assembly...................................................................................3601 How to Remove Operator Cab Assembly....................................................................................3601 How to Install Operator Cab Assembly...................................................................................3609 Remove and Install Operator Cab Glass (Adhered Glass)......................................................................3617 How to Remove Operator CAB Glass (Adhered Glass).......................................................................3619 How to Install Operator Cab Glass (Adhered Glass)......................................................................3619 Remove and Install Front Window Assembly...................................................................................3629 Remove Front Window Assembly...........................................................................................3629 Install Front Window Assembly..........................................................................................3632 Remove and Install Floor Frame Assembly....................................................................................3638 How to Remove Floor Frame Assembly.....................................................................................3638 How to Install Floor Frame Assembly....................................................................................3641 Remove and Install Air Conditioner Unit Assembly...........................................................................3646 How to Remove Air Conditioner Unit Assembly............................................................................3646 How to Install Air Conditioner Unit Assembly...........................................................................3651 Remove and Install Operator Seat...........................................................................................3657 How to Remove Operator Seat............................................................................................3657 How to Install Operator Seat...........................................................................................3659 How to Remove and Install Seat Belt........................................................................................3662 How to Remove Seat Belt................................................................................................3662 How to Install Seatbelt................................................................................................3662 Remove and Install Front Wiper Assembly....................................................................................3664 Remove Front Wiper Assembly............................................................................................3664 How to Install Front Wiper Assembly....................................................................................3669 Electrical System..............................................................................................................3678 Remove and Install Engine Controller Assembly..............................................................................3678 How to Remove Engine Controller Assembly...............................................................................3678 How to Install Engine Controller Assembly..............................................................................3681 Remove and Install Pump Controller1 Assembly...............................................................................3684 How to Remove Pump Controller1 Assembly................................................................................3684 How to Install Pump Controller1 Assembly...............................................................................3685 Remove and Install Pump Controller2 Assembly...............................................................................3686 How to Remove Pump Controller2 Assembly................................................................................3686 How to Install Pump Controller2 Assembly...............................................................................3688 Remove and Install Pump Controller3 Assembly...............................................................................3691 How to Remove Pump Controller3 Assembly................................................................................3691 How to Install Pump Controller3 Assembly...............................................................................3692 Remove and Install KomVision Controller Assembly...........................................................................3693 Remove KomVision Controller Assembly...................................................................................3693 Install KomVision Controller Assembly..................................................................................3694 Remove and Install Machine Monitor Assembly................................................................................3695 How to Remove Machine Monitor Assembly.................................................................................3695 How to Install Machine Monitor Assembly................................................................................3697 Remove and Install Mass Air Flow and Temperature Sensor....................................................................3701 How to Remove Mass Air Flow and Temperature Sensor.....................................................................3702 How to Install Mass Air Flow and Temperature Sensor....................................................................3702 Remove and Install KCCV Crankcase Pressure Sensor..........................................................................3704 How to Remove KCCV Crankcase Pressure Sensor...........................................................................3704 How to Install KCCV Crankcase Pressure Sensor..........................................................................3705 Remove and Install KDPF Temperature Sensor.................................................................................3707 How to Remove KDPF Temperature Sensor..................................................................................3707 How to Install KDPF Temperature Sensor.................................................................................3710 Remove and Install KDPF Differential Pressure Sensor.......................................................................3714 How to Remove KDPF Differential Pressure Sensor........................................................................3714 How to Install KDPF Differential Pressure Sensor.......................................................................3716 Remove and Install SCR Temperature Sensor..................................................................................3719 How to Remove SCR Temperature Sensor...................................................................................3719 How to Install SCR Temperature Sensor..................................................................................3722 Remove and Install Ammonia Sensor..........................................................................................3725 How to Remove Ammonia Sensor...........................................................................................3725 How to Install Ammonia Sensor..........................................................................................3727 Remove and Install SCR Outlet NOx Sensor...................................................................................3729 How to Remove SCR Outlet NOx Sensor....................................................................................3729 How to Install SCR Outlet NOx Sensor...................................................................................3731 Remove and Install KomVision Camera........................................................................................3733 How to Remove KomVision Camera.........................................................................................3733 How to Install KomVision Camera........................................................................................3734 Remove and Install Gateway Function Controller Assembly....................................................................3736 How to Remove Gateway Function Controller Assembly.....................................................................3736 How to Install Gateway Function Controller Assembly....................................................................3738 60 Maintenance Standard............................................................................................................3741 Table of Contents..............................................................................................................3742 Engine and Cooling System......................................................................................................3744 Maintenance Standard for Engine Mount......................................................................................3744 Maintenance Standard for PTO...............................................................................................3745 Maintenance Standard for Cooling System....................................................................................3747 Maintenance Standard of Cooling Fan Pump of Oil Cooler.....................................................................3748 Maintenance Standard for Servo Valve...................................................................................3749 Maintenance Standard of Cooling Fan Motor of Radiator......................................................................3751 Maintenance Standard of Cooling Fan Motor of Oil Cooler....................................................................3754 Power Train....................................................................................................................3756 Maintenance Standard for Swing Circle......................................................................................3756 Maintenance Standard for Swing Machinery...................................................................................3757 Maintenance Standard for Final Drive (PC900LC-11)..........................................................................3759 Maintenance Standard for Final Drive (PC950-11E0, PC950LC-11E0)............................................................3761 Maintenance Standard for Sprocket (PC900LC-11).............................................................................3763 Maintenance Standard for Sprocket (PC950-11E0, PC950LC-11E0)...............................................................3764 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing (PC900LC-11)............................................3765 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing (PC950-11E0, PC950LC-11E0)..............................3767 Undercarriage and Frame........................................................................................................3768 Maintenance Standard of Track Frame and Idler Cushion (PC900LC-11).........................................................3768 Maintenance Standard of Track Frame and Idler Cushion (PC950-11E0, PC950LC-11E0)...........................................3770 Maintenance Standard for Idler (PC900LC-11)................................................................................3772 Maintenance Standard for Idler (PC950-11E0, PC950LC-11E0)..................................................................3774 Maintenance Standard for Track Roller (PC900LC-11).........................................................................3776 Maintenance Standard for Track Roller (PC950-11E0, PC950LC-11E0)...........................................................3777 Maintenance Standard for Carrier Roller (PC900LC-11).......................................................................3778 Maintenance Standard for Carrier Roller (PC950-11E0, PC950LC-11E0).........................................................3779 Maintenance Standard for Track Shoes (PC900LC-11)..........................................................................3780 Maintenance Standard for Track Shoes (PC950-11E0, PC950LC-11E0)............................................................3783 Maintenance Standard for Double Shoes (PC900LC-11).........................................................................3786 Maintenance Standard for Double Shoes (PC950-11E0, PC950LC-11E0)...........................................................3787 Hydraulic System...............................................................................................................3788 Maintenance Standard for Main Pump.........................................................................................3788 Maintenance Standard for Main Pump Servo Valve.........................................................................3792 Maintenance Standard for Main Pump EPC Valve...........................................................................3794 Maintenance Standard of Swing Pump.........................................................................................3795 Maintenance Standard of EPC Valve of Swing Pump........................................................................3796 Maintenance Standard of Neutral Hold Valve.................................................................................3797 Maintenance Standard of EPC Valve of Neutral Hold Valve................................................................3800 Maintenance Standard of Charge Pump and Radiator Cooling Fan Pump..........................................................3801 Maintenance Standard for Swing Motor.......................................................................................3803 Maintenance Standard for Swing Junction Valve..............................................................................3805 Maintenance Standard for Travel Motor (PC900LC-11).........................................................................3806 Maintenance Standard for Travel Motor (PC950-11E0, PC950LC-11E0)...........................................................3809 Maintenance Standard for Control Valve.....................................................................................3812 Maintenance Standard for Variable Back Pressure Valve......................................................................3825 Maintenance Standard for Counterweight Remover Cylinder....................................................................3826 Maintenance Standard of Boom Regeneration Valve............................................................................3827 Maintenance Standard of Lock Valve (Common to Boom Lock Valve and Arm Lock Valve)..........................................3828 Maintenance Standard of Quick Return Valve.................................................................................3830 Maintenance Standard for Work Equipment and Swing PPC Valve................................................................3832 Maintenance Standard for Travel PPC Valve..................................................................................3834 Maintenance Standard for Solenoid Valve....................................................................................3836 Maintenance Standard for Center Swivel Joint...............................................................................3837 Maintenance Standard for Arm Anti-Drop Valve...............................................................................3838 Work Equipment.................................................................................................................3840 Maintenance Standard for Work Equipment Linkage............................................................................3840 Dimensions of Arm (PC900LC-11).........................................................................................3845 Dimensions of Arm (PC950-11E0, PC950LC-11E0)...........................................................................3847 Dimensions of Arm (PC900LC-11, PC950-11E0, PC950LC-11E0)(SE)...........................................................3849 Dimensions of Bucket (PC900LC-11)......................................................................................3851 Dimensions of Bucket (PC950-11E0, PC950LC-11E0)........................................................................3853 Dimensions of Bucket (PC900LC-11, PC950-11E0, PC950LC-11E0)(SE)........................................................3855 Maintenance Standard for Boom Cylinder.....................................................................................3857 Maintenance Standard for Arm Cylinder (PC900LC-11, PC950-11E0, PC950LC-11E0)...............................................3858 Maintenance Standard for Arm Cylinder (PC900LC-11, PC950-11E0, PC950LC-11E0)(SE)...........................................3859 Maintenance Standard for Bucket Cylinder (PC900LC-11, PC950-11E0, PC950LC-11E0)............................................3860 Maintenance Standard for Bucket Cylinder (PC900LC-11, PC950-11E0, PC950LC-11E0)(SE)........................................3861 80 Appendix........................................................................................................................3863 Table of Contents..............................................................................................................3864 Precautions Before Work........................................................................................................3866 Air Conditioner System.........................................................................................................3867 Precautions for Refrigerant................................................................................................3867 Air Conditioner Component..................................................................................................3868 Specifications of Air Conditioner..........................................................................................3870 Structure and Function of Refrigeration Cycle..............................................................................3871 Outline of Refrigeration Cycle.............................................................................................3872 Component Parts of Air Conditioner System......................................................................................3874 Air Conditioner Unit.......................................................................................................3874 Configuration Diagram of Air Conditioner Unit..........................................................................3874 Function of Air Conditioner Unit.......................................................................................3876 Component Parts of Air Conditioner Unit....................................................................................3878 Function of Evaporator as Air Conditioner Unit Component...............................................................3879 Function of Heater Core as Air Conditioner Unit Component..............................................................3879 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component............................................3879 Function of Servo Motor as Air Conditioner Unit Component..............................................................3879 Structure of Expansion Valve as Air Conditioner Unit Component.........................................................3880 Function of Expansion Valve as Air Conditioner Unit Component..........................................................3880 Operate Expansion Valve as Air Conditioner Unit Component..............................................................3880 Function of Dual Pressure Switch.......................................................................................3881 Air Conditioner Controller.................................................................................................3882 Structure of Air Conditioner Controller................................................................................3882 Compressor.................................................................................................................3883 Structure of Compressor................................................................................................3883 Specifications of Compressor...........................................................................................3883 Function of Compressor.................................................................................................3883 Condenser..................................................................................................................3884 Structure of Condenser.................................................................................................3884 Specifications of Condenser............................................................................................3884 Function of Condenser..................................................................................................3884 Receiver Drier.............................................................................................................3885 Structure of Receiver Dryer............................................................................................3885 Specifications of Receiver Dryer.......................................................................................3885 Function of Receiver Dryer.............................................................................................3885 Air Conditioner Related Sensors............................................................................................3886 Structure of Sunlight Sensor...........................................................................................3886 Function of Sunlight Sensor............................................................................................3886 Structure of Outside Temperature Sensor................................................................................3886 Function of Outside Air Temperature Sensor.............................................................................3886 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner....................................................3888 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.........................................................3890 System Diagram of Air Conditioner..............................................................................................3892 Input and Output Signals of Air Conditioner Controller.....................................................................3893 Function of Air Conditioner Controller.................................................................................3894 Locations of Air Conditioner Parts and Layout of Connectors....................................................................3895 Examine Air Leakage (Duct).....................................................................................................3899 How to Examine Air Leakage (Duct)..........................................................................................3899 Examine Air Conditioner with Self-Diagnosis Function...........................................................................3901 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor........................................3902 Examine Vent (Mode) Changeover.................................................................................................3903 How to Examine Vent (Mode) Changeover......................................................................................3903 Examine Fresh/Recirc Air Changeover............................................................................................3905 How to Examine Fresh/Recirc Air Changeover.................................................................................3905 Examine Sunlight Sensor........................................................................................................3906 How to Examine Sunlight Sensor.............................................................................................3906 Examine Refrigerant (Dual) Pressure Switch.....................................................................................3907 How to Examine Refrigerant (Dual) Pressure Switch..........................................................................3907 Examine Relay..................................................................................................................3908 How to Examine Relay.......................................................................................................3908 Air Conditioner Troubleshooting Chart 1........................................................................................3909 Air Conditioner Troubleshooting Chart 2........................................................................................3910 Information Shown in Troubleshooting Table.....................................................................................3913 Failure Code [879AKA]..........................................................................................................3914 Failure Code [879AKB]..........................................................................................................3915 Failure Code [879BKA]..........................................................................................................3916 Failure Code [879BKB]..........................................................................................................3918 Failure Code [879CKA]..........................................................................................................3920 Failure Code [879CKB]..........................................................................................................3921 Failure Code [879DKZ]..........................................................................................................3922 Failure Code [879EMC]..........................................................................................................3924 Failure Code [879FMC]..........................................................................................................3925 Failure Code [879GKX]..........................................................................................................3926 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate).....................................................3928 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)......................................................3930 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal).............................................3933 Troubleshooting for Fresh/Recirc Air Changeover................................................................................3935 Troubleshooting by Gauge Pressure..............................................................................................3937 Connect Service Tool...........................................................................................................3940 How to Connect Service Tool................................................................................................3940 Precautions for Disconnection and Connection of Air Conditioner Piping.........................................................3942 Handle Compressor Oil..........................................................................................................3944 90 Circuit Diagrams................................................................................................................3947 Table of Contents..............................................................................................................3948 How to Read the Codes for Electric Cable.......................................................................................3950 Hydraulic Circuit Diagram......................................................................................................3954 Symbols Used in Hydraulic Circuit Diagram..................................................................................3954 Hydraulic Circuit Diagram (PC900LC-11).....................................................................................3959 Hydraulic Circuit Diagram (PC950-11E0, PC950LC-11E0).......................................................................3961 Electrical Circuit Diagram.....................................................................................................3963 Symbols Used in Electric Circuit Diagram...................................................................................3963 Electrical Circuit Diagram (1/25) (PC900LC-11).............................................................................3967 Electrical Circuit Diagram (2/25) (PC900LC-11).............................................................................3969 Electrical Circuit Diagram (3/25) (PC900LC-11).............................................................................3971 Electrical Circuit Diagram (4/25) (PC900LC-11).............................................................................3973 Electrical Circuit Diagram (5/25) (PC900LC-11).............................................................................3975 Electrical Circuit Diagram (6/25) (PC900LC-11).............................................................................3977 Electrical Circuit Diagram (7/25) (PC900LC-11).............................................................................3979 Electrical Circuit Diagram (8/25) (PC900LC-11).............................................................................3981 Electrical Circuit Diagram (9/25) (PC900LC-11).............................................................................3983 Electrical Circuit Diagram (10/25) (PC900LC-11)............................................................................3985 Electrical Circuit Diagram (11/25) (PC900LC-11)............................................................................3987 Electrical Circuit Diagram (12/25) (PC900LC-11)............................................................................3989 Electrical Circuit Diagram (13/25) (PC900LC-11)............................................................................3991 Electrical Circuit Diagram (14/25) (PC900LC-11)............................................................................3993 Electrical Circuit Diagram (15/25) (PC900LC-11)............................................................................3995 Electrical Circuit Diagram (16/25) (PC900LC-11)............................................................................3997 Electrical Circuit Diagram (17/25) (PC900LC-11)............................................................................3999 Electrical Circuit Diagram (18/25) (PC900LC-11)............................................................................4001 Electrical Circuit Diagram (19/25) (PC900LC-11)............................................................................4003 Electrical Circuit Diagram (20/25) (PC900LC-11)............................................................................4005 Electrical Circuit Diagram (21/25) (PC900LC-11)............................................................................4007 Electrical Circuit Diagram (22/25) (PC900LC-11)............................................................................4009 Electrical Circuit Diagram (23/25) (PC900LC-11)............................................................................4011 Electrical Circuit Diagram (24/25) (PC900LC-11)............................................................................4013 Electrical Circuit Diagram (25/25) (PC900LC-11)............................................................................4015 Electrical Circuit Diagram (1/26) (PC950-11E0, PC950LC-11E0)...............................................................4017 Electrical Circuit Diagram (2/26) (PC950-11E0, PC950LC-11E0)...............................................................4019 Electrical Circuit Diagram (3/26) (PC950-11E0, PC950LC-11E0)...............................................................4021 Electrical Circuit Diagram (4/26) (PC950-11E0, PC950LC-11E0)...............................................................4023 Electrical Circuit Diagram (5/26) (PC950-11E0, PC950LC-11E0)...............................................................4025 Electrical Circuit Diagram (6/26) (PC950-11E0, PC950LC-11E0)...............................................................4027 Electrical Circuit Diagram (7/26) (PC950-11E0, PC950LC-11E0)...............................................................4029 Electrical Circuit Diagram (8/26) (PC950-11E0, PC950LC-11E0)...............................................................4031 Electrical Circuit Diagram (9/26)(PC950-11E0, PC950LC-11E0)................................................................4033 Electrical Circuit Diagram (10/26) (PC950-11E0, PC950LC-11E0)..............................................................4035 Electrical Circuit Diagram (11/26) (PC950-11E0, PC950LC-11E0)..............................................................4037 Electrical Circuit Diagram (12/26) (PC950-11E0, PC950LC-11E0)..............................................................4039 Electrical Circuit Diagram (13/26) (PC950-11E0, PC950LC-11E0)..............................................................4041 Electrical Circuit Diagram (14/26) (PC950-11E0, PC950LC-11E0)..............................................................4043 Electrical Circuit Diagram (15/26) (PC950-11E0, PC950LC-11E0)..............................................................4045 Electrical Circuit Diagram (16/26) (PC950-11E0, PC950LC-11E0)..............................................................4047 Electrical Circuit Diagram (17/26) (PC950-11E0, PC950LC-11E0)..............................................................4049 Electrical Circuit Diagram (18/26) (PC950-11E0, PC950LC-11E0)..............................................................4051 Electrical Circuit Diagram (19/26)(PC950-11E0, PC950LC-11E0)...............................................................4053 Electrical Circuit Diagram (20/26)(PC950-11E0, PC950LC-11E0)...............................................................4055 Electrical Circuit Diagram (21/26) (PC950-11E0, PC950LC-11E0)..............................................................4057 Electrical Circuit Diagram (22/26) (PC950-11E0, PC950LC-11E0)..............................................................4059 Electrical Circuit Diagram (23/26) (PC950-11E0, PC950LC-11E0)..............................................................4061 Electrical Circuit Diagram (24/26) (PC950-11E0, PC950LC-11E0)..............................................................4063 Electrical Circuit Diagram (25/26) (PC950-11E0, PC950LC-11E0)..............................................................4065 Electrical Circuit Diagram (26/26) (PC950-11E0, PC950LC-11E0)..............................................................4067 Index...............................................................................................................................4069
DESCRIPTION:
KOMATSU PC900LC-11 PC950-11E0 PC950LC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06968-02 – PDF DOWNLOAD
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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
S.S 31/12/24
