Komatsu Hydraulic Excavator PC210LC-11 Shop Manual SEN06516-17 PDF

Description

Komatsu Hydraulic Excavator PC210LC-11 Shop Manual SEN06516-17  – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC210LC-11 Shop Manual SEN06516-17  – PDF DOWNLOAD

Language : English
Pages : 2902
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC210LC-11 Shop Manual SEN06516-17  – PDF DOWNLOAD

• SERIAL NUMBERS 500001 and up

Cover . 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials . 37
Procedures for Exhaust Gas Regulations . 38
Precautions for DEF 39
General Character and Precautions for Handling . 39
Precautions for Adding . 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment . 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX . 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors . 59
How to Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
How to Disconnect and Connect Connector with Lock to Pull 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate . 69
How to Read the Codes for Electric Cable . 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table . 77
Conversion Table . 84
01 Specifications 89
Table of Contents 90
Specifications . 91
Specification Drawing 91
Specification Drawing: PC210LC-11 91
Working Range Drawings . 93
Working Range: PC210LC-11 93
Specifications . 94
Specifications: PC210LC-11 . 94
Weight Table . 97
Weight Table: PC210LC-11 . 97
Table of Fuel, Coolant, and Lubricants . 99
Fuel, Coolant, Lubricant . 100
How to Use Fuel, Coolant and Lubricants by Ambient Temperature . 100
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 108
Urea SCR System Diagram 113
Function of Urea SCR System 114
Function of DEF System . 114
Inducement Strategy 116
Component Parts of Urea SCR System . 130
DEF Mixing Tube 130
SCR Assembly . 131
DEF Tank . 133
DEF Pump . 135
DEF Injector . 136
DEF Hose . 137
DEF Tank Heating Valve . 138
Boot-up System . 139
Layout Drawing of Boot-up System . 139
System Operating Lamp System . 141
System Diagram of System Operating Lamp System . 141
Function of Operation Lamp System 141
Battery Disconnect Switch 143
Function of Battery Disconnect Switch 143
Engine System 144
Layout Drawing of Engine System 144
Specifications of Engine System 145
Function of Engine System 145
Engine Control System 146
System Diagram of Engine Control . 146
Function of Engine Control System 147
Auto-Deceleration System . 149
System Diagram of Auto-Deceleration System . 149
Function of Auto-Deceleration System . 149
Operation of Auto-Deceleration System 150
Engine Automatic Warm-up System 151
System Diagram of Engine Automatic Warm-up System 151
Function of Engine Automatic Warm-up System 152
Overheat Prevention System . 153
Overheat Prevention System Diagram . 153
Function of Overheat Prevention System . 154
Turbocharger Protection System . 156
System Diagram of Turbocharger Protection System . 156
Function of Turbocharger Protection System . 157
Automatic Idle Stop System . 158
System Diagram of Automatic Idle Stop System . 158
Function of Automatic Idle Stop System . 158
Component Parts of Engine System . 161
VGT 161
EGR System . 166
EGR Valve 168
EGR Cooler . 170
KCCV System 172
KCCV Ventilator 174
KDPF . 176
Cooling System . 180
Layout Drawing of Cooling System . 180
Specifications of Cooling System . 181
Fan Speed Control System of Fan Clutch . 182
Fan Speed Control System Diagram of Fan Clutch . 182
Function of Fan Speed Control System of Fan Clutch . 183
Engine Output Control System of Fan Clutch . 184
Engine Output Control System Diagram of Fan Clutch . 184
Function of Engine Output Control System of Fan Clutch . 184
Component Parts of Cooling System 186
Fan Clutch . 186
Control System . 187
Layout Drawing of Control System . 187
Machine Monitor System . 190
System Diagram of Machine Monitor System . 190
KomVision System . 191
Layout Drawing of KomVision System . 191
System Diagram of KomVision System . 193
Function of KomVision System . 193
KOMTRAX System . 195
System Diagram of KOMTRAX System . 195
Function of KOMTRAX System . 195
Component Parts of Control System 196
Machine Monitor 196
KomVision Controller . 211
KomVision Camera . 215
KOMTRAX Terminal . 215
Pump Controller 218
Resistor for PC-EPC Valve 222
CAN Terminating Resistor . 223
Engine Controller 224
Fuel Control Dial 231
Hydraulic System . 233
Layout Drawing of Hydraulic System . 233
CLSS . 239
Structure of CLSS 239
Operation of Unload Valve and LS Pressure 241
Pump Swash Plate Angle (Oil Flow) Control 242
Pressure Compensation Control 258
Engine and Pump Combined Control System 262
Engine and Pump Combined Control System Diagram 262
Function of Engine and Pump Combined Control System 263
Pump and Valve Control System 268
Pump and Valve Control System Diagram 268
Function of Pump and Valve Control System 269
Component Parts of Hydraulic System 271
Hydraulic Tank . 271
Main Pump 273
Control Valve 299
Work Equipment System 358
Layout Drawing of Work Equipment System 358
Structure of Valve Control . 363
One-Touch Power Maximizing System 365
System Diagram of One-Touch Power Maximizing System 365
Function of One-Touch Power Maximizing System 366
PPC Lock System 367
System Diagram of PPC Lock . 367
Function of PPC Lock System 367
Work Equipment and Travel Automatic Lock System 368
System Diagram of Lock Lever Automatic Lock System . 368
Function of Work Equipment and Travel Automatic Lock System 368
Operation of Lock Lever Automatic Lock System 369
Attachment Oil Flow Adjuster System 370
Attachment Oil Flow Adjuster System Diagram 370
Function of Attachment Oil Flow Adjuster System 371
Tool Control System 372
Tool Control System Diagram 372
Component Parts of Work Equipment System . 374
Work Equipment and Swing PPC Valve . 374
1st-Line Attachment PPC Valve (with EPC Valve) . 381
2nd-Line Attachment PPC Valve 389
Solenoid Valve . 391
Boom Anti-drop Valve . 394
Arm Anti-Drop Valve 398
Attachment Circuit Selector Valve (For High Pressure) 403
Attachment Circuit Selector Valve (For Low Pressure) . 405
1st-Line Attachment Variable Relief Valve 406
2nd-Line Attachment Variable Relief Valve 409
Attachment Bypass Solenoid Valve . 412
Pilot Circuit Accumulator 414
Attachment Circuit Accumulator . 415
Swing System . 416
Layout Drawing of Swing System . 416
Swing Control System Diagram . 420
Function of Swing Control System . 420
Component Parts of Swing System 424
Swing Motor 424
Swing Machinery 436
Swing Circle . 438
Travel System 439
Layout Drawing of Travel System 439
System Diagram of Travel Control System 443
Function of Travel Control System 444
Component Parts of Travel System . 445
Travel Motor . 445
Final Drive 457
Travel PPC Valve . 460
Center Swivel Joint 464
Undercarriage and Frame 466
Layout Drawing of Undercarriage 466
Specifications of Undercarriage 467
Work Equipment . 468
Structure of Work Equipment 468
Function of Work Equipment . 468
Work Equipment Clearance Adjustment Shim . 469
Function of Work Equipment Clearance Adjustment Shim . 469
Bucket Clearance Adjustment Shim . 469
Function of Bucket Clearance Adjustment Shim . 469
CAB Related Parts 470
ROPS CAB . 470
Structure of ROPS CAB 470
Function of ROPS CAB . 470
CAB Mount 471
Structure of CAB Mount . 471
Function of CAB Mount 471
CAB Tipping Stopper 472
Structure of CAB Tipping Stopper . 472
Function of CAB Tipping Stopper 472
20 Standard Value Table 473
Table of Contents 474
Standard Value Table for Engine 475
Standard Value Table for Engine: PC210LC-11 475
Standard Value Table for Machine . 479
Standard Value Table for Machine: PC210LC-11 . 479
Machine Posture and Procedures to Measure Performance 492
Standard Value Table for Electricity . 496
Standard Value Table for Electricity . 496
30 Testing and Adjusting . 507
Table of Contents 508
Precautions Before Work 511
Related Information on Testing and Adjusting . 512
Tools for Testing and Adjusting 512
Sketch of Tools for Testing and Adjusting 519
Engine and Cooling System 521
Examine Engine Speed . 521
How to Examine Engine Speed 521
Examine Boost Pressure . 524
How to Examine Boost Pressure on Machine Monitor . 524
How to Examine Boost Pressure by Testing Tool 525
Examine Exhaust Gas Color 526
How to Examine Exhaust Gas Color with the Handy Smoke Checker 526
How to Examine Exhaust Gas Color with Smoke Meter 527
Examine Mass Air Flow and Temperature Sensor . 529
How to Examine Mass Air Flow and Temperature Sensor 529
Examine and Adjust Valve Clearance . 531
How to Examine Valve Clearance . 531
How to Adjust Valve Clearance 532
Examine Compression Pressure . 534
How to Examine Compression Pressure 534
Examine Blowby Pressure 539
How to Examine Blowby Pressure . 539
Examine Engine Oil Pressure 541
How to Examine Engine Oil Pressure . 541
Examine EGR Valve and VGT Oil Pressure . 542
How to Examine EGR Valve and VGT Oil Pressure 542
Examine Fuel Pressure 544
How to Examine Fuel Pressure . 545
Examine Fuel Discharge, Return and Leakage . 550
How to Examine Fuel Discharge, Return, and Leakage . 551
Bleed Air from Fuel System . 557
How to Bleed Air from Fuel System 557
Examine Fuel Circuit for Leakage . 558
How to Examine Fuel System for Leakage . 558
Handle Cylinder Cut-out Mode Operation . 560
Handle No-Injection Cranking Operation . 561
Examine and Adjust Air Conditioner Compressor Belt Tension . 562
How to Examine Air Conditioner Compressor Belt . 562
How to Adjust Air Conditioner Compressor Belt 562
Examine Fan Belt and Alternator Belt . 564
How to Examine Fan Belt and Alternator Belt 564
Examine Automatic Tensioner 565
How to Examine Automatic Tensioner . 565
Examine Cooling Fan Speed 566
How to Examine Cooling Fan Speed . 566
Write Correction for Ash in Soot Accumulation to Engine Controller . 567
How to Write Correction for Ash in Soot Accumulation to Engine Controller 567
Examine SCR Related Functions 568
Examine DEF Pump Raised Pressure . 572
Examine Injection Volume from DEF Injector . 575
Examine DEF Line Heater Relay 1 580
Examine DEF Line Heater Relay 2 583
Examine DEF Pump Heater Relay 586
Examine DEF Tank Heater Valve 589
Examine SCR Denitration Efficiency . 592
Clean DEF Tank . 596
How to Clean DEF Tank 596
Clean DEF Pump . 600
How to Clean DEF Pump 600
Bleed Air from Coolant Circuit of DEF Tank . 607
How to Bleed Air from Coolant Circuit of DEF Tank 607
Power Train 609
Examine Swing Circle Bearing Clearance . 609
How to Examine Swing Circle Bearing Clearance 609
Undercarriage and Frame 610
Examine and Adjust Track Tension . 610
How to Examine Track Tension . 610
How to Adjust Track Tension 610
Hydraulic System . 612
Release Remained Pressure in Hydraulic Circuit . 612
How to Release Remained Pressure in Hydraulic System . 612
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 613
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 614
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . 620
Examine Oil Pressure of Control Circuit 623
How to Examine Oil Pressure in Control Circuit . 623
Examine and adjust oil pressure in pump PC control circuit . 625
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) . 625
Examine PC-EPC Valve Outlet Pressure . 626
How to Adjust Oil Pressure in Pump PC Control Circuit 627
Examine and Adjust Oil Pressure in Pump LS Control Circuit . 629
How to Examine LS Differential Pressure with Machine Monitor . 629
How to Examine LS Differential Pressure by Testing Tool 630
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 633
How to Examine LS-EPC Valve Outlet Pressure 634
How to Adjust LS Valve . 635
Examine Outlet Pressure of Solenoid Valve 636
How to Examine Outlet Pressure of Solenoid Valve . 636
Operating Condition of Solenoid Valve 637
Examine PPC Valve Outlet Pressure 640
How to Examine Outlet Pressure in PPC Valve 640
Examine Attachment Circuit Oil Pressure 642
How to Examine Attachment Circuit Oil Pressure . 642
Adjust Play of Work Equipment and Swing PPC Valves . 643
How to Adjust Play of Work Equipment and Swing PPC Valves 643
Examine Pump Swash Plate Sensor 644
How to Examine pump swash plate sensor . 644
Examine Parts Which Cause Hydraulic Drift of Work Equipment 645
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 645
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder . 645
How to Examine Parts that Cause Hydraulic Drift of PPC Valve . 646
Examine Oil Leakage 647
How to Examine Oil Leakage from Boom Cylinder 647
How to Examine Oil Leakage from Arm Cylinder . 647
How to Examine Oil Leakage from Bucket Cylinder 648
How to Examine Oil Leakage from Swing Motor 649
How to Examine Oil Leakage from Travel Motor . 649
Bleed Air from Hydraulic System 650
How to Bleed Air from Hydraulic System . 652
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 654
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 654
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) . 658
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) . 658
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 662
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping . 662
CAB Related Parts 669
Examine CAB Tipping Stopper 669
How to Examine Cab Tipping Stopper . 669
How to Adjust Mirrors 670
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 670
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) . 671
Procedure to Adjust Machine Right Side Mirror (C) 672
Electrical System 674
Set and Operate Machine Monitor 674
Operator Mode 678
Function to Show Technician Identification Status Screen . 678
Function to Show Operator Identification Input Screen 678
Examine Function by LCD (Liquid Crystal Display) . 679
Examine Function of Service Meter 679
Usage Limitation and Maintenance Password Change Function 679
Service Mode . 682
How to Operate Service Mode 682
How to See Pre-defined Monitoring Information 684
How to Examine Self-Define Monitor Information . 691
Abnormality Record Menu 702
How to See Maintenance Record 706
Maintenance Mode Setting . 707
How to Set Phone Number Entry 711
Default Menu . 713
Diagnostic Tests Menu 725
Adjustment Menu 734
No-Injection Cranking Operation 765
KOMTRAX Settings Menu 767
How to Show Service Message 769
How to Start Up KOMTRAX Terminal . 771
Adjust Rearview Camera Angle . 776
How to Adjust Rearview Camera Angle 776
Adjust KomVision Camera Angle 779
How to Adjust KomVision Camera Angle . 780
Adjust KomVision Related Function 784
Setting of KomVision (Main Setting) 784
Setting of KomVision (Camera Setting) 786
Setting of KomVision (Camera Calibration) 788
KomVision screen – Check 12 m visibility . 801
Set Region of Bluetooth(R) Compatible Radio 804
How to Set Region of Bluetooth(R) Compatible Radio . 804
Handle Voltage Circuit of Engine Controller 806
Handle Battery Disconnect Switch . 807
Examine Diodes . 808
How to Examine Diodes by Digital Tester 808
How to Examine Diodes by Analog Tester . 808
Pm Clinic 809
Pm Clinic Service 809
Pm Clinic Check Sheet 811
40 Troubleshooting . 823
Table of Contents 824
Precautions Before Work 834
Related Information to Troubleshooting . 835
General Troubleshooting Points . 835
Troubleshooting Points for Urea SCR System . 836
Sequence of Events in Troubleshooting 850
Checks Before Troubleshooting 852
Inspection Procedure Before Troubleshooting 854
Walk-Around Check 854
Test in Accordance with Testing Procedure 856
Examine Fuel Level and Type 856
Examine for Impure Ingredient in Fuel 856
Examine Fuel Prefilter . 857
Examine Water Separator, Drain Water and Sediment 857
How to Replace Fuel Prefilter Cartridge 858
Examine Fuel Main Filter . 859
Examine Engine Oil Level (Oil Quantity in Oil Pan) . 861
Examine Coolant Level (Reservoir Tank) . 862
Examine Air Cleaner Clogging . 862
Clean Outer Element 863
Replace Element 865
Examine Hydraulic Oil Level 866
Examine Hydraulic Oil Strainer . 867
Examine Hydraulic Oil Filter . 868
Examine Oil Level in Swing Machinery Case 869
Examine Oil Level in Damper Case . 870
Examine Oil Level in Final Drive Case 870
Bleed Air from Fuel System . 871
Bleed Air from Hydraulic System 871
How to Examine Electric Equipment 871
Preparation for Troubleshooting of Electrical System . 879
Procedure for Troubleshooting 889
Symptom and Troubleshooting Numbers 892
Information Shown in Troubleshooting Table . 896
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 898
Connector List and Layout 901
Connector Contact Connection Table . 914
T-Branch Box and T-Branch Adapter Table 954
Fuse Location Table 960
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 962
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) . 966
Failure Code Table . 968
Troubleshooting by Failure Code (Display of Code) 986
Failure Code [879AKA] 986
Failure Code [879AKB] 987
Failure Code [879BKA] 988
Failure Code [879BKB] 990
Failure Code [879CKA] 992
Failure Code [879CKB] 993
Failure Code [879DKZ] 994
Failure Code [879EMC] 996
Failure Code [879FMC] 997
Failure Code [879GKX] 998
Failure Code [989L00] 1000
Failure Code [989M00] 1001
Failure Code [989N00] 1002
Failure Code [A1U0N3] 1003
Failure Code [A1U0N4] 1005
Failure Code [A900FR] 1007
Failure Code [A900N6] 1008
Failure Code [A900NY] 1009
Failure Code [AA10NX] 1010
Failure Code [AB00KE] 1012
Failure Code [AQ10N3] 1015
Failure Code [AS00N3] 1017
Failure Code [AS00R2] 1019
Failure Code [AS00R3] 1020
Failure Code [AS00R4] 1021
Failure Code [AS00R5] 1022
Failure Code [AS00R6] 1023
Failure Code [AS00ZK] 1024
Failure Code [AS10KM] 1025
Failure Code [AS10NR] 1026
Failure Code [AS10NT] 1027
Failure Code [B@BAZG] 1028
Failure Code [B@BAZK] 1029
Failure Code [B@BCNS] 1031
Failure Code [B@BCQA] 1032
Failure Code [B@BCZK] 1034
Failure Code [B@HANS] 1036
Failure Code [CA115] .1037
Failure Code [CA122] .1038
Failure Code [CA123] .1040
Failure Code [CA131] .1042
Failure Code [CA132] .1044
Failure Code [CA144] .1046
Failure Code [CA145] .1048
Failure Code [CA153] .1050
Failure Code [CA154] .1053
Failure Code [CA187] .1055
Failure Code [CA221] .1057
Failure Code [CA222] .1059
Failure Code [CA227] .1061
Failure Code [CA234] .1062
Failure Code [CA238] .1063
Failure Code [CA239] .1065
Failure Code [CA249] .1067
Failure Code [CA256] .1069
Failure Code [CA271] .1071
Failure Code [CA272] .1073
Failure Code [CA322] .1075
Failure Code [CA323] .1077
Failure Code [CA324] .1079
Failure Code [CA325] .1081
Failure Code [CA331] .1083
Failure Code [CA332] .1085
Failure Code [CA343] .1087
Failure Code [CA351] .1088
Failure Code [CA352] .1089
Failure Code [CA356] .1092
Failure Code [CA357] .1094
Failure Code [CA386] .1096
Failure Code [CA428] .1097
Failure Code [CA429] .1099
Failure Code [CA435] .1101
Failure Code [CA441] .1103
Failure Code [CA442] .1105
Failure Code [CA449] .1106
Failure Code [CA451] .1107
Failure Code [CA452] .1109
Failure Code [CA488] .1111
Failure Code [CA515] .1112
Failure Code [CA516] .1114
Failure Code [CA553] .1116
Failure Code [CA555] .1117
Failure Code [CA556] .1118
Failure Code [CA559] .1119
Failure Code [CA595] .1122
Failure Code [CA687] .1123
Failure Code [CA689] .1125
Failure Code [CA691] .1128
Failure Code [CA692] .1130
Failure Code [CA697] .1132
Failure Code [CA698] .1133
Failure Code [CA731] .1134
Failure Code [CA778] .1136
Failure Code [CA1117] 1141
Failure Code [CA1664] 1142
Failure Code [CA1669] 1144
Failure Code [CA1673] 1145
Failure Code [CA1677] 1146
Failure Code [CA1678] 1147
Failure Code [CA1682] 1148
Failure Code [CA1683] 1150
Failure Code [CA1684] 1152
Failure Code [CA1686] 1154
Failure Code [CA1691] 1155
Failure Code [CA1694] 1158
Failure Code [CA1695] 1161
Failure Code [CA1696] 1162
Failure Code [CA1712] 1164
Failure Code [CA1713] 1167
Failure Code [CA1714] 1169
Failure Code [CA1715] 1170
Failure Code [CA1776] 1171
Failure Code [CA1777] 1174
Failure Code [CA1843] 1177
Failure Code [CA1844] 1179
Failure Code [CA1879] 1182
Failure Code [CA1881] 1184
Failure Code [CA1883] 1186
Failure Code [CA1885] 1189
Failure Code [CA1887] 1191
Failure Code [CA1921] 1193
Failure Code [CA1922] 1196
Failure Code [CA1942] 1201
Failure Code [CA1993] 1202
Failure Code [CA2185] 1205
Failure Code [CA2186] 1206
Failure Code [CA2249] 1208
Failure Code [CA2271] 1209
Failure Code [CA2272] 1212
Failure Code [CA2288] 1215
Failure Code [CA2311] 1216
Failure Code [CA2349] 1217
Failure Code [CA2353] 1220
Failure Code [CA2357] 1222
Failure Code [CA2381] 1223
Failure Code [CA2382] 1226
Failure Code [CA2383] 1229
Failure Code [CA2386] 1232
Failure Code [CA2387] 1234
Troubleshooting Flowchart 1238
Failure Code [CA2555] 1239
Failure Code [CA2556] 1242
Failure Code [CA2637] 1245
Failure Code [CA2639] 1247
Failure Code [CA2771] 1250
Failure Code [CA2777] 1256
Failure Code [CA2976] 1259
Failure Code [CA3133] 1261
Failure Code [CA3134] 1264
Failure Code [CA3135] 1266
Failure Code [CA3142] 1269
Failure Code [CA3143] 1270
Failure Code [CA3144] 1271
Failure Code [CA3146] 1273
Failure Code [CA3147] 1274
Failure Code [CA3148] 1275
Failure Code [CA3151] 1277
Failure Code [CA3165] 1283
Failure Code [CA3229] 1285
Failure Code [CA3231] 1287
Failure Code [CA3232] 1289
Failure Code [CA3235] 1293
Failure Code [CA3239] 1295
Failure Code [CA3241] 1298
Failure Code [CA3242] 1301
Failure Code [CA3251] 1304
Failure Code [CA3253] 1306
Failure Code [CA3254] 1309
Failure Code [CA3255] 1312
Failure Code [CA3256] 1316
Failure Code [CA3311] 1318
Failure Code [CA3312] 1320
Failure Code [CA3313] 1323
Failure Code [CA3314] 1324
Failure Code [CA3315] 1325
Failure Code [CA3316] 1327
Failure Code [CA3317] 1328
Failure Code [CA3318] 1329
Failure Code [CA3319] 1331
Failure Code [CA3321] 1332
Failure Code [CA3322] 1334
Failure Code [CA3419] 1336
Failure Code [CA3421] 1338
Failure Code [CA3497] 1340
Failure Code [CA3498] 1341
Failure Code [CA3543] 1342
Failure Code [CA3545] 1349
Failure Code [CA3547] 1351
Failure Code [CA3558] 1352
Failure Code [CA3559] 1354
Failure Code [CA3562] 1356
Failure Code [CA3563] 1358
Failure Code [CA3567] 1361
Failure Code [CA3568] 1364
Failure Code [CA3571] 1368
Failure Code [CA3572] 1370
Failure Code [CA3574] 1372
Failure Code [CA3575] 1374
Failure Code [CA3577] 1376
Failure Code [CA3578] 1378
Failure Code [CA3582] 1380
Failure Code [CA3583] 1386
Failure Code [CA3596] 1388
Failure Code [CA3649] 1390
Failure Code [CA3681] 1392
Failure Code [CA3682] 1397
Failure Code [CA3713] 1403
Failure Code [CA3717] 1406
Failure Code [CA3718] 1407
Failure Code [CA3725] 1408
Failure Code [CA3741] 1411
Failure Code [CA3748] 1412
Failure Code [CA3751] 1414
Failure Code [CA3755] 1416
Failure Code [CA3866] 1418
Failure Code [CA3867] 1422
Failure Code [CA3868] 1425
Failure Code [CA3899] 1429
Failure Code [CA3911] 1431
Failure Code [CA3912] 1435
Failure Code [CA3932] 1437
Failure Code [CA3933] 1439
Failure Code [CA3934] 1441
Failure Code [CA3935] 1444
Failure Code [CA3936] 1446
Failure Code [CA4151] 1448
Failure Code [CA4152] 1452
Failure Code [CA4155] 1456
Failure Code [CA4156] 1458
Failure Code [CA4157] 1461
Failure Code [CA4158] 1463
Failure Code [CA4159] 1464
Failure Code [CA4161] 1465
Failure Code [CA4162] 1468
Failure Code [CA4163] 1471
Failure Code [CA4164] 1472
Failure Code [CA4165] 1474
Failure Code [CA4166] 1476
Failure Code [CA4168] 1477
Failure Code [CA4169] 1480
Failure Code [CA4171] 1482
Failure Code [CA4249] 1485
Failure Code [CA4251] 1487
Failure Code [CA4259] 1489
Failure Code [CA4261] 1492
Failure Code [CA4277] 1495
Failure Code [CA4281] 1498
Failure Code [CA4459] 1501
Failure Code [CA4461] 1503
Failure Code [CA4658] 1506
Failure Code [CA4731] 1510
Failure Code [CA4732] 1511
Failure Code [CA4739] 1512
Failure Code [CA4768] 1513
Failure Code [CA4769] 1515
Failure Code [CA4842] 1518
Failure Code [CA4952] 1522
Failure Code [CA5115] 1524
Failure Code [CA5179] 1527
Failure Code [CA5181] 1529
Failure Code [CA5383] 1531
Failure Code [D110KB] 1533
Failure Code [D19JKZ] 1535
Failure Code [D811MC] 1538
Failure Code [D862KA] 1539
Failure Code [D8ALKA] 1540
Failure Code [D8ALKB] 1542
Failure Code [D8AQKR] 1544
Failure Code [DA20MC] 1546
Failure Code [DA22KK] 1547
Failure Code [DA25KP] 1550
Failure Code [DA26KP] 1553
Failure Code [DA29KQ] 1556
Failure Code [DA2LKA] 1558
Failure Code [DA2LKB] 1560
Failure Code [DA2QKR] 1562
Failure Code [DA2RKR] 1565
Failure Code [DAF0KM] 1566
Failure Code [DAF0MB] 1567
Failure Code [DAF0MC] 1568
Failure Code [DAF8KB] 1569
Failure Code [DAF9KQ] 1571
Failure Code [DAFGMC] 1572
Failure Code [DAFLKA] 1573
Failure Code [DAFLKB] 1575
Failure Code [DAFQKR] 1577
Failure Code [DAZ9KQ] 1578
Failure Code [DAZQKR] 1579
Failure Code [DB2QKR] 1584
Failure Code [DB2RKR] 1589
Failure Code [DBP0KM] 1594
Failure Code [DBP0KT] 1595
Failure Code [DBP5KB] 1596
Failure Code [DBP5KY] 1599
Failure Code [DBPQKR] 1602
Failure Code [DDNRKA] 1607
Failure Code [DDNRKY] 1609
Failure Code [DDNS00] 1611
Failure Code [DGH2KA] 1613
Failure Code [DGH2KB] 1615
Failure Code [DHA4KA] 1617
Failure Code [DHAAMA] 1619
Failure Code [DHACMA] 1621
Failure Code [DHPAMA] 1623
Failure Code [DHPBMA] 1626
Failure Code [DHS3MA] 1629
Failure Code [DHS4MA] 1632
Failure Code [DHS8MA] 1635
Failure Code [DHS9MA] 1638
Failure Code [DHSAMA] 1641
Failure Code [DHSBMA] 1644
Failure Code [DHSCMA] 1647
Failure Code [DHSDMA] 1650
Failure Code [DHSFMA] 1653
Failure Code [DHSGMA] 1656
Failure Code [DHSHMA] 1659
Failure Code [DHSJMA] 1662
Failure Code [DHZAMA] 1665
Failure Code [DHZCL8] 1669
Failure Code [DKR0MA] 1670
Failure Code [DKR1MA] 1673
Failure Code [DKULKA] 1676
Failure Code [DKULKB] 1678
Failure Code [DKULKY] 1680
Failure Code [DLM5KA] 1682
Failure Code [DLM5MB] 1684
Failure Code [DR10KA] 1686
Failure Code [DR12KA] 1689
Failure Code [DR20KA] 1691
Failure Code [DR21KX] 1693
Failure Code [DR30KA] 1695
Failure Code [DR31KX] 1697
Failure Code [DR40KA] 1699
Failure Code [DUMBKA] 1701
Failure Code [DUMBKB] 1703
Failure Code [DV20KB] 1705
Failure Code [DW43KA] 1707
Failure Code [DW43KB] 1709
Failure Code [DW43KY] 1711
Failure Code [DW45KA] 1713
Failure Code [DW45KB] 1716
Failure Code [DW45KY] 1719
Failure Code [DW4CKY] 1721
Failure Code [DW91KA] 1723
Failure Code [DW91KB] 1725
Failure Code [DW91KY] 1727
Failure Code [DWA2KA] 1729
Failure Code [DWA2KB] 1731
Failure Code [DWA2KY] 1733
Failure Code [DWK0KA] 1735
Failure Code [DWK0KB] 1737
Failure Code [DWK0KY] 1739
Failure Code [DWK2KA] 1741
Failure Code [DWK2KB] 1743
Failure Code [DWK2KY] 1745
Failure Code [DWK8KA] 1747
Failure Code [DWK8KB] 1749
Failure Code [DWK8KY] 1751
Failure Code [DWN5KA] 1753
Failure Code [DWN5KB] 1755
Failure Code [DWN5KY] 1757
Failure Code [DWPUKA] 1759
Failure Code [DWPUKB] 1761
Failure Code [DWPUKY] 1763
Failure Code [DXA8KA] 1765
Failure Code [DXA8KB] 1767
Failure Code [DXA9KA] 1769
Failure Code [DXA9KB] 1771
Failure Code [DXE0KA] 1773
Failure Code [DXE0KB] 1775
Failure Code [DXE4KA] 1777
Failure Code [DXE4KB] 1779
Failure Code [DXE4KY] 1781
Failure Code [DXE5KA] 1783
Failure Code [DXE5KB] 1785
Failure Code [DXE6KA] 1787
Failure Code [DXE6KB] 1789
Failure Code [DXE7KA] 1791
Failure Code [DXE7KB] 1793
Failure Code [DXE7KY] 1795
Failure Code [DXE8KA] 1797
Failure Code [DXE8KB] 1799
Failure Code [DXE8KY] 1801
Failure Code [DXE9KA] 1803
Failure Code [DXE9KB] 1805
Failure Code [DXE9KY] 1807
Failure Code [DXEAKA] 1809
Failure Code [DXEAKB] 1811
Failure Code [DXEAKY] 1813
Failure Code [DXEKKA] 1815
Failure Code [DXEKKB] 1817
Failure Code [DXEKKY] 1819
Failure Code [DXELKA] 1821
Failure Code [DXELKB] 1823
Failure Code [DXELKY] 1825
Failure Code [DY20KA] 1827
Failure Code [DY20MA] 1829
Failure Code [DY2CKB] 1831
Failure Code [DY2DKB] 1834
Failure Code [DY2EKB] 1836
Troubleshooting of Electrical System (E-Mode) 1838
E-1 Engine Does Not Start (Engine Does Not Crank) 1838
E-2 Manual Preheating System Does Not Operate 1844
E-3 Automatic Preheating System Does Not Operate .1847
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1849
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing .1851
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1854
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1855
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation .1856
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1857
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs .1858
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation .1859
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1860
E-13 Water Separator Monitor Comes On in Red While Engine Runs .1861
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1862
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1863
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1864
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1865
E-18 Display of Fuel Gauge is Different from Actual Fuel Level .1867
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum .1868
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature .1869
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum .1870
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature .1872
E-23 Some Areas of Machine Monitor Screen are Not Shown 1873
E-24 Function Switch Does Not Operate 1874
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1875
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1876
E-27 Auto-Decelerator is Not Operated or Canceled with Lever .1877
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1878
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed .1879
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1880
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change .1881
E-32 Alarm Buzzer Cannot be Canceled .1883
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1884
E-34 Service Mode Cannot be Selected .1885
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1886
E-36 All Work Equipment, Swing and Travel Do Not Lock 1889
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1891
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1894
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show .1896
E-40 One-Touch Power Maximizing Function is Not Cancelled 1899
E-41 Alarm Does Not Sound During Travel 1900
E-42 Alarm Does Not Stop When Machine Stops 1902
E-43 Horn Does Not Sound .1903
E-44 Horn Does Not Stop 1906
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out .1908
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1909
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1911
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1912
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1913
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function .1914
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1915
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function .1916
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function .1917
E-54 “Swing” is Not Shown Correctly with Monitoring Function .1918
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1919
E-56 Service is Not Shown Correctly with Monitoring Function .1920
E-57 Attachment Hydraulic Circuit Cannot be Changed 1922
E-58 KOMTRAX System Does Not Operate Correctly .1923
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1924
Information Shown in Troubleshooting Table (H-Mode) 1924
System Chart of Hydraulic and Mechanical Systems .1925
Failure Mode and Cause Table .1927
H-1 All Work Equipment, Swing and Travel Do Not Work .1936
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1937
H-3 Fine Control Performance or Response is Unsatisfactory .1940
H-4 Unusual Noise is Heard from Around Hydraulic Pump 1941
H-5 Engine Speed Drops Largely or Engine Stops .1942
H-6 Speed or Power of Boom is Low 1944
H-7 Arm Speed or Power is Low 1948
H-8 Bucket Speed or Power is Low .1953
H-9 Work Equipment Does Not Move in Single Operation .1956
H-10 Hydraulic Drift of Boom is Large 1957
H-11 Hydraulic Drift of Arm is Large .1959
H-12 Hydraulic Drift of Bucket is Large 1961
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1962
H-14 Time Lag of Work Equipment is Large .1963
H-15 One-Touch Power Maximizing Function Does Not Operate 1964
H-16 Attachment Circuit Cannot be Changed 1965
H-17 Oil Flow in Attachment Circuit Cannot be Changed 1966
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower .1967
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 1968
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low .1969
H-21 Machine Does Not Travel Straight 1970
H-22 Machine is Not Steered Correctly or Steering Power is Low .1972
H-23 Travel Speed is Low .1975
H-24 One of Tracks Does Not Run 1977
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast .1978
H-26 Upper Structure Does Not Swing to Right and Left 1979
H-27 Upper Structure Swings Only to Right or Left 1980
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions .1981
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 1982
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1983
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1984
H-32 Shock is Large When Upper Structure Stops Swing Operation .1985
H-33 There is Large Unusual Noise When It Stops Swing Operation 1986
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1987
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) .1988
H-1 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1989
H-37 Unusual Noise is Heard from Around Fan 1990
Troubleshooting of Engine (S-Mode) .1991
Information Shown in Troubleshooting Table (S-Mode) 1991
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position .1992
S-2 Engine Cranks but No Exhaust Smoke Comes Out .1993
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .1994
S-4 Engine Startability is Unsatisfactory 1996
S-5 Engine Does Not Pick Up Smoothly .1998
S-6 Engine Stops During Operation 2000
S-7 Engine Runs Rough or is Not Stable .2002
S-8 Engine Lacks Power .2003
S-9 KDPF Becomes Clogged in a Short Time .2005
S-10 Engine Oil Consumption is Excessive .2007
S-11 Oil Becomes Dirty Quickly .2008
S-12 Fuel Consumption is Excessive .2009
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2010
S-14 Oil Pressure Drops 2011
S-15 Fuel Mixes Into Engine Oil 2013
S-16 Water Mixes Into Engine Oil (Milky) .2014
S-17 Coolant Temperature Increases Too High (Overheating) 2015
S-18 Unusual Noise is Heard 2016
S-19 Vibration is Excessive 2017
S-20 Air Cannot be Bled from Fuel Circuit 2018
S-21 Active Regeneration is Done Frequently 2019
S-22 Active Regeneration Continues Long 2021
S-23 White Smoke is Exhausted During Active Regeneration .2022
S-24 DEF Consumption is Excessive 2023
S-25 There is Unusual Smell (Irritating Odor) 2025
S-26 Foreign Materials Enter DEF (DEF Increases) .2026
50 Disassembly and Assembly 2027
Table of Contents 2028
Precautions Before Work 2033
Related Information on Disassembly and Assembly 2034
How to Read This Manual 2034
Coating Materials List .2035
Special Tool List 2040
Sketches of Special Tools 2049
Engine and Cooling System 2055
Remove and Install Supply Pump Assembly 2055
How to Remove Supply Pump Assembly .2055
How to Install Supply Pump Assembly 2057
Remove and Install Injector Assembly .2061
How to Remove Injector Assembly 2061
How to Install Injector Assembly .2066
Remove and Install Cylinder Head Assembly 2075
How to Remove Cylinder Head Assembly .2076
How to Install Cylinder Head Assembly 2089
Remove and Install EGR Valve Assembly 2108
How to Remove EGR Valve Assembly .2108
How to Install EGR Valve Assembly 2110
Remove and Install EGR Cooler Assembly .2112
How to Remove EGR Cooler Assembly 2112
How to Install EGR Cooler Assembly .2117
Remove and Install Starter Assembly 2124
How to Remove Starting Motor Assembly 2124
How to Install Starting Motor Assembly .2126
Remove and Install Alternator Belt .2129
How to Remove Alternator Belt 2129
How to Install Alternator Belt .2132
Remove and Install Radiator Assembly .2135
How to Remove Radiator Assembly 2135
How to Install Radiator Assembly .2138
Remove and Install Hydraulic Oil Cooler Assembly .2142
How to Remove Hydraulic Oil Cooler Assembly 2142
How to Install Hydraulic Oil Cooler Assembly .2148
Remove and Install Aftercooler Assembly 2153
How to Remove Aftercooler Assembly .2153
How to Install Aftercooler Assembly 2155
Remove and Install Fan Clutch Assembly .2157
How to Remove Fan Clutch Assembly 2157
How to Install Fan Clutch Assembly .2161
Remove and Install Fan .2166
How to Remove Fan 2166
How to Install Fan .2166
Remove and Install Engine and Main Pump Assembly .2167
How to Remove Engine and Main Pump Assembly 2167
How to Install Engine and Main Pump Assembly .2177
Remove and Install Engine Front Oil Seal .2189
How to Remove Engine Front Oil Seal 2189
How to Install Engine Front Oil Seal .2193
Remove and Install Engine Rear Oil Seal 2198
How to Remove Engine Rear Oil Seal .2198
How to Install Engine Rear Oil Seal 2199
Remove and Install Fuel Cooler Assembly 2203
How to Remove Fuel Cooler Assembly .2203
How to Install Fuel Cooler Assembly 2204
Remove and Install Engine Hood Assembly 2205
How to Remove Engine Hood Assembly .2205
How to Install Engine Hood Assembly 2207
Remove and Install Fuel Tank Assembly 2212
How to Remove Fuel Tank Assembly .2212
How to Install Fuel Tank Assembly 2216
Remove and Install DEF Tank Assembly .2221
How to Remove DEF Tank Assembly 2221
How to Install DEF Tank Assembly .2227
Remove and Install DEF Tank Sensor Flange Assembly .2234
How to Remove DEF Tank Sensor Flange Assembly 2234
How to Install DEF Tank Sensor Flange Assembly .2241
Remove and Install DEF Tank Sensor .2247
How to Remove DEF Tank Sensor 2247
How to Install DEF Tank Sensor .2248
Remove and Install DEF Tank Strainer .2254
How to Remove DEF Tank Strainer 2254
How to Install DEF Tank Strainer .2254
Remove and Install DEF Tank Filler Port Filter .2256
How to Remove DEF Tank Filler Port Filter 2256
How to Install DEF Tank Filler Port Filter .2258
Remove and Install KDPF Assembly .2261
How to Remove KDPF Assembly 2261
How to Install KDPF Assembly .2263
Disassemble and Assemble KDPF Assembly .2265
How to Disassemble KDPF Assembly .2265
How to Assemble KDPF Assembly 2268
Remove and Install SCR Assembly 2273
How to Remove SCR Assembly .2273
How to Install SCR Assembly 2275
Remove and Install KDPF and SCR Assembly .2277
How to Remove KDPF and SCR Assembly 2277
How to Install KDPF and SCR Assembly .2283
Remove and Install KDPF and SCR Assembly Bracket .2289
How to Remove KDPF and SCR Assembly Bracket 2289
How to Install KDPF and SCR Assembly Bracket .2296
Remove and Install Bellows Pipe Assembly .2303
How to Remove Bellows Pipe Assembly 2303
How to Install Bellows Pipe Assembly .2305
Remove and Install KCCV Assembly .2309
How to Remove KCCV Assembly 2309
How to Install KCCV Assembly .2312
Remove and Install DEF Mixing Tube .2316
How to Remove DEF Mixing Tube 2316
How to Install DEF Mixing Tube .2322
Remove and Install DEF Injector 2330
How to Remove DEF Injector .2330
How to Install DEF Injector 2334
Remove and Install DEF Pump 2338
How to Remove DEF Pump .2338
How to Install DEF Pump 2342
Remove and Install DEF Hose 2345
How to Remove DEF Hose .2345
How to Install DEF Hose 2352
Remove and Install Air Cleaner Assembly 2359
How to Remove Air Cleaner Assembly .2359
How to Install Air Cleaner Assembly 2361
Remove and Install Air Conditioner Compressor Assembly .2363
How to Remove Air Conditioner Compressor Assembly 2363
How to Install Air Conditioner Compressor Assembly .2365
Remove and Install Air Conditioner Condenser Assembly 2369
How to Remove Air Conditioner Condenser Assembly .2369
How to Install Air Conditioner Condenser Assembly 2370
Power Train 2372
Remove and Install Travel Motor and Final Drive Assembly .2372
How to Remove Travel Motor and Final Drive Assembly 2372
How to Install Travel Motor and Final Drive Assembly .2374
Disassemble and Assemble Final Drive Assembly 2376
How to Disassemble Final Drive Assembly 2376
How to Assemble Final Drive Assembly .2381
Remove and Install Swing Motor and Swing Machinery Assembly 2391
How to Remove Swing Motor and Swing Machinery Assembly .2391
How to Install Swing Motor and Swing Machinery Assembly 2394
Disassemble and Assemble Swing Machinery Assembly 2397
How to Disassemble Swing Machinery Assembly 2397
How to Assemble Swing Machinery Assembly .2404
Remove and Install Swing Circle Assembly .2414
How to Remove Swing Circle Assembly 2414
How to Install Swing Circle Assembly .2414
Undercarriage and Frame 2416
Separate and Connect Track Assembly 2416
How to Separate Track Assembly .2416
How to Install Track Assembly 2418
Remove and Install Sprocket 2422
How to Remove Sprocket .2422
How to Install Sprocket 2422
Remove and Install Idler and Idler Cushion Assembly 2424
How to Remove Idler and Idler Cushion Assembly .2424
How to Install Idler and Idler Cushion Assembly 2425
Disassemble and Assemble Idler Assembly 2426
How to Disassemble Idler Assembly 2426
How to Assemble Idler Assembly .2428
Disassemble and Assemble Idler Cushion Assembly 2435
How to Disassemble Idler Cushion Assembly 2436
How to Assemble Idler Cushion Assembly .2437
Disassemble and Assemble Track Roller Assembly .2439
How to Disassemble Track Roller Assembly .2439
How to Assemble Track Roller Assembly 2440
Disassemble and Assemble Carrier Roller Assembly .2442
How to Disassemble Carrier Roller Assembly .2442
How to Assemble Carrier Roller Assembly 2444
Remove and Install Revolving Frame Assembly 2447
How to Remove Revolving Frame Assembly .2447
How to Install Revolving Frame Assembly 2449
Remove and Install Counterweight Assembly 2452
How to Remove Counterweight Assembly .2452
How to Install Counterweight Assembly 2455
Hydraulic System .2459
Remove and Install Center Swivel Joint Assembly 2459
How to Remove Center Swivel Joint Assembly .2459
How to Install Center Swivel Joint Assembly 2462
Disassemble and Assemble Center Swivel Joint Assembly 2465
How to Disassemble Center Swivel Joint Assembly 2465
How to Assemble Center Swivel Joint Assembly .2466
Remove and Install Hydraulic Tank Assembly .2469
How to Remove Hydraulic Tank Assembly 2469
How to Install Hydraulic Tank Assembly .2472
Remove and Install Main Pump Assembly 2476
How to Remove Main Pump Assembly .2476
How to Install Main Pump Assembly 2479
Remove and Install Control Valve Assembly 2483
How to Remove Control Valve Assembly .2483
How to Install Control Valve Assembly 2491
Disassemble and Assemble Control Valve Assembly 2499
How to Replace Pressure Compensation Valve Seal Ring .2499
How to Assemble Control Valve Assembly .2501
Disassemble and Assemble Work Equipment PPC Valve Assembly .2506
How to Disassemble Work Equipment PPC Valve Assembly .2506
How to Assemble Work Equipment PPC Valve Assembly 2506
Disassemble and Assemble Travel PPC Valve Assembly .2509
How to Disassemble Travel PPC Valve Assembly .2509
How to Assemble Travel PPC Valve Assembly 2510
Work Equipment .2512
Remove and Install Work Equipment Assembly .2512
How to Remove Work Equipment Assembly 2512
How to Install Work Equipment Assembly .2518
Remove and Install Boom Anti-drop Valve Assembly .2524
How to Remove Boom Anti-drop Valve Assembly 2524
How to Install Boom Anti-drop Valve Assembly .2526
Remove and Install Arm Anti-Drop Valve Assembly 2528
How to Remove Arm Anti-Drop Valve Assembly .2528
How to Install Arm Anti-Drop Valve Assembly 2530
Disassemble and Assemble Anti-Drop Valve Assembly 2532
How to Disassemble Anti-Drop Valve Assembly 2532
How to Assemble Anti-Drop Valve Assembly .2532
Disassemble and Assemble Work Equipment Cylinder Assembly 2533
How to Disassemble Work Equipment Cylinder Assembly 2534
How to Assemble Work Equipment Cylinder Assembly .2538
CAB Related Parts 2545
Remove and Install Operator Cab Assembly .2545
How to Remove Operator Cab Assembly 2545
How to Install Operator Cab Assembly .2553
Remove and Install Operator Cab Glass (Adhered Glass) 2563
How to Remove Operator Cab Glass (Adhered Glass) .2565
How to Install Operator Cab Glass (Adhered Glass) 2565
Remove and Install Front Window Assembly .2576
How to Remove Front Window Assembly 2576
How to Install Front Window Assembly .2579
Remove and Install Floor Frame Assembly 2585
How to Remove Floor Frame Assembly .2585
How to Install Floor Frame Assembly 2593
Remove and Install Air Conditioner Unit Assembly .2603
How to Remove Air Conditioner Unit Assembly 2603
How to Install Air Conditioner Unit Assembly .2610
Remove and Install Operator Seat .2617
How to Remove Operator Seat 2617
How to Install Operator Seat .2619
How to Remove and Install Seat Belt 2622
How to Remove Seat Belt 2622
How to Install Seatbelt 2623
Remove and Install Work Equipment Control Lever Assembly .2624
How to Remove Work Equipment Control Lever Assembly 2624
How to Install Work Equipment Control Lever Assembly .2630
Remove and Install Front Wiper Assembly 2639
How to Remove Front Wiper Assembly .2639
How to Install Front Wiper Assembly 2644
Electrical System 2652
Remove and Install Engine Controller Assembly 2652
How to Remove Engine Controller Assembly .2652
How to Install Engine Controller Assembly 2654
Remove and Install Pump Controller Assembly 2656
How to Remove Pump Controller Assembly .2656
How to Install Pump Controller Assembly 2660
Remove and Install KomVision Controller Assembly .2665
How to Remove KomVision Controller Assembly 2665
How to Install KomVision Controller Assembly .2666
Remove and Install Machine Monitor Assembly 2667
How to Remove Machine Monitor Assembly .2667
How to Install Machine Monitor Assembly 2670
Remove and Install Pump Swash Plate Sensor .2673
How to Remove Pump Swash Plate Sensor 2673
How to Install Pump Swash Plate Sensor .2674
Remove and Install Mass Air Flow and Temperature Sensor 2676
How to Remove Mass Air Flow and Temperature Sensor .2676
How to Install Mass Air Flow and Temperature Sensor 2677
Remove and Install KCCV Crankcase Pressure Sensor 2679
How to Remove KCCV Crankcase Pressure Sensor .2679
How to Install KCCV Crankcase Pressure Sensor 2680
Remove and Install SCR Temperature Sensor 2681
How to Remove SCR Temperature Sensor .2681
How to Install SCR Temperature Sensor 2683
Remove and Install KomVision Camera 2685
How to Remove KomVision Camera .2685
How to Install KomVision Camera 2686
Remove and Install KOMTRAX Terminal Assembly .2688
How to Remove KOMTRAX Terminal Assembly 2688
How to Install KOMTRAX Terminal Assembly .2691
60 Maintenance Standard 2695
Table of Contents 2696
Engine and Cooling System 2697
Maintenance Standard for Engine Mount 2697
Maintenance Standard for Cooling System 2698
Power Train 2700
Maintenance Standard for Swing Circle 2700
Maintenance Standard for Swing Machinery .2701
Maintenance Standard for Final Drive .2703
Maintenance Standard for Sprocket 2705
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing .2706
Undercarriage and Frame 2707
Maintenance Standard for Track Frame and Idler Cushion .2707
Maintenance Standard for Idler .2709
Maintenance Standard for Track Roller 2711
Maintenance Standard for Carrier Roller 2712
Maintenance Standard for Track Shoes .2713
Maintenance Standard for Triple Shoes 2716
Maintenance Standard for Swamp Shoes .2717
Maintenance Standard for Road Liner 2718
Hydraulic System .2719
Maintenance Standard for Hydraulic Tank 2719
Maintenance Standard for Main Pump .2720
Maintenance Standard for LS-EPC Valve 2721
Maintenance Standard for PC-EPC Valve 2722
Maintenance Standard for Swing Motor .2723
Maintenance Standard for Travel Motor 2726
Maintenance Standard for Control Valve .2729
Maintenance Standard for Boom Anti-Drop Valve 2739
Maintenance Standard for Arm Anti-Drop Valve .2741
Maintenance Standard for Work Equipment and Swing PPC Valve 2743
Maintenance Standard for Travel PPC Valve 2746
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2749
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2750
Maintenance Standard for 2nd-Line Attachment PPC Valve .2752
Maintenance Standard for Solenoid Valve 2754
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) .2755
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2756
Maintenance Standard for Center Swivel Joint .2757
Work Equipment .2758
Maintenance Standard for Work Equipment Linkage 2758
Dimensions of Arm 2763
Dimensions of Bucket .2765
Maintenance Standard for Boom Cylinder (Large Diameter Piston) .2767
Maintenance Standard for Arm Cylinder 2768
Maintenance Standard for Bucket Cylinder .2769
80 Appendix 2771
Table of Contents 2772
Precautions Before Work 2774
Air Conditioner System .2775
Precautions for Refrigerant 2775
Air Conditioner Component 2776
Specifications of Air Conditioner 2778
Structure and Function of Refrigeration Cycle 2779
Outline of Refrigeration Cycle .2780
Component Parts of Air Conditioner System 2782
Air Conditioner Unit .2782
Configuration Diagram of Air Conditioner Unit 2782
Function of Air Conditioner Unit .2784
Component Parts of Air Conditioner Unit 2786
Function of Evaporator as Air Conditioner Unit Component .2787
Function of Heater Core as Air Conditioner Unit Component 2787
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2787
Function of Servo Motor as Air Conditioner Unit Component 2787
Structure of Expansion Valve as Air Conditioner Unit Component .2788
Function of Expansion Valve as Air Conditioner Unit Component 2788
Operate Expansion Valve as Air Conditioner Unit Component 2788
Function of Dual Pressure Switch .2789
Air Conditioner Controller .2790
Structure of Air Conditioner Controller 2790
Compressor .2791
Structure of Compressor 2791
Specifications of Compressor .2791
Function of Compressor .2791
Condenser 2792
Structure of Condenser .2792
Specifications of Condenser 2792
Function of Condenser 2792
Air Conditioner Related Sensors 2794
Structure of Sunlight Sensor .2794
Function of Sunlight Sensor 2794
Structure of Outside Temperature Sensor 2794
Function of Outside Air Temperature Sensor .2794
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2796
Circuit Diagram and Configuration of Connector Pins of Air Conditioner .2798
System Diagram of Air Conditioner 2800
Input and Output Signals of Air Conditioner Controller .2801
Function of Air Conditioner Controller .2802
Locations of Air Conditioner Parts and Layout of Connectors 2803
Examine Air Leakage (Duct) .2807
How to Examine Air Leakage (Duct) 2807
Examine Air Conditioner with Self-Diagnosis Function .2809
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2810
Examine Vent (Mode) Changeover .2811
How to Examine Vent (Mode) Changeover 2811
Examine Fresh/Recirc Air Changeover 2813
How to Examine Fresh/Recirc Air Changeover .2813
Examine Sunlight Sensor 2814
How to Examine Sunlight Sensor .2814
Examine Refrigerant (Dual) Pressure Switch .2815
How to Examine Refrigerant (Dual) Pressure Switch 2815
Examine Relay 2816
How to Examine Relay .2816
Air Conditioner Troubleshooting Chart 1 2817
Air Conditioner Troubleshooting Chart 2 2818
Information Shown in Troubleshooting Table .2821
Failure Code [879AKA] 2822
Failure Code [879AKB] 2823
Failure Code [879BKA] 2824
Failure Code [879BKB] 2826
Failure Code [879CKA] 2828
Failure Code [879CKB] 2829
Failure Code [879DKZ] 2830
Failure Code [879EMC] 2832
Failure Code [879FMC] 2833
Failure Code [879GKX] 2834
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) .2836
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2838
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) .2841
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2843
Troubleshooting by Gauge Pressure 2845
Connect Service Tool .2848
How to Connect Service Tool 2848
Precautions for Disconnection and Connection of Air Conditioner Piping .2850
Handle Compressor Oil 2852
How to Replace Desiccant .2854
90 Circuit Diagrams 2857
Table of Contents 2858
Hydraulic Circuit Diagram 2859
Symbols Used in Hydraulic Circuit Diagram 2859
Hydraulic Circuit Diagram 2863
Electrical Circuit Diagram .2865
Symbols Used in Electric Circuit Diagram .2865
Electrical Circuit Diagram (1/7) .2869
Electrical Circuit Diagram (2/7) .2871
Electrical Circuit Diagram (3/7) .2873
Electrical Circuit Diagram (4/7) .2875
Electrical Circuit Diagram (5/7) .2877
Electrical Circuit Diagram (6/7) .2879
Electrical Circuit Diagram (7/7) .2881
Index .2883

DESCRIPTION:

Komatsu Hydraulic Excavator PC210LC-11 Shop Manual SEN06516-17  – PDF DOWNLOAD

• SERIAL NUMBERS 500001 and up

G.B 27/12/24