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KOMATSU PC1250-11 PC1250SP-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06657-10 – PDF DOWNLOAD
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KOMATSU PC1250-11 PC1250SP-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06657-10 – PDF DOWNLOAD
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KOMATSU PC1250-11 PC1250SP-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06657-10 – PDF DOWNLOAD
Language : English
Pages : 2924
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File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC1250-11 PC1250SP-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06657-10 – PDF DOWNLOAD
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 When You Discard Waste Materials........................................................................................................ 37 Precautions When You Handle Hydraulic Equipment..................................................................................................... 38 Precautions When You Disconnect and Connect Pipings................................................................................................. 41 Precautions When You Handle Electrical Equipment.................................................................................................... 47 Precautions When You Handle Fuel System Equipment................................................................................................... 49 Precautions When You Handle Intake System Equipment................................................................................................. 50 Practical Use of KOMTRAX............................................................................................................................ 51 Disconnect and Connect Push-Pull Type Coupler....................................................................................................... 52 How to Disconnect and Connect Type 1 Push-Pull Type Coupler..................................................................................... 52 How to Disconnect and Connect Type 2 Push-Pull Type Coupler..................................................................................... 53 How to Disconnect and Connect Type 3 Push-Pull Type Coupler..................................................................................... 54 Precautions for Disconnection and Connection of Connectors.......................................................................................... 56 How to Disconnect and Connect Deutsch Connector..................................................................................................... 60 How to Disconnect and Connect Slide Lock Type Connector............................................................................................. 61 How to Disconnect and Connect Connector with Lock to Pull........................................................................................... 63 How to Disconnect and Connect Connector with Lock to Push........................................................................................... 64 How to Disconnect and Connect Connector with Housing to Rotate...................................................................................... 66 How to Read the Codes for Electric Cable............................................................................................................ 67 Explanation of Terms for Maintenance Standard....................................................................................................... 71 Standard Tightening Torque Table.................................................................................................................... 74 Conversion Table.................................................................................................................................... 81 01 Specifications........................................................................................................................................... 87 Table of Contents....................................................................................................................................... 88 Specifications.......................................................................................................................................... 89 Specification Drawing............................................................................................................................... 89 Specification Drawing: PC1250-11................................................................................................................ 89 Specification Drawing: PC1250SP-11.............................................................................................................. 90 Specification Drawing: PC1250-11 (Loading Shovel Specification)................................................................................. 91 Working Range Drawings.............................................................................................................................. 92 Working Range: PC1250-11........................................................................................................................ 92 Working Range: PC1250SP-11...................................................................................................................... 93 Working Range: PC1250-11 (Loading Shovel Specification)......................................................................................... 94 Specifications...................................................................................................................................... 95 Specifications: PC1250-11....................................................................................................................... 95 Specifications: PC1250SP-11..................................................................................................................... 98 Specifications: PC1250-11 (Loading Shovel Specification)........................................................................................ 101 Weight Table........................................................................................................................................ 105 Weight Table: PC1250-11......................................................................................................................... 105 Weight Table: PC1250SP-11....................................................................................................................... 107 Weight Table: PC1250-11 (Loading Shovel Specification).......................................................................................... 109 Fuel, Coolant, Lubricants (For European Union)...................................................................................................... 111 How to Use Fuel, Coolant and Lubricants by Ambient Temperature.................................................................................. 111 10 Structure and Function................................................................................................................................... 113 Table of Contents....................................................................................................................................... 114 Boot-up System.......................................................................................................................................... 118 Layout Drawing of Boot-up System.................................................................................................................... 118 System Operating Lamp System........................................................................................................................ 119 System Diagram of System Operating Lamp System.................................................................................................. 119 Function of Operation Lamp System............................................................................................................... 119 Battery Disconnect Switch........................................................................................................................... 121 Function of Battery Disconnect Switch........................................................................................................... 121 Engine System........................................................................................................................................... 122 Layout Drawing of Engine System..................................................................................................................... 122 Function of Engine System....................................................................................................................... 124 Engine Control System............................................................................................................................... 125 System Diagram of Engine Control................................................................................................................ 125 Function of Engine Control System............................................................................................................... 125 Auto-Deceleration System............................................................................................................................ 128 System Diagram of Auto-Deceleration System...................................................................................................... 128 Function of Auto-Deceleration System............................................................................................................ 128 Operation of Auto-Deceleration System........................................................................................................... 129 Automatic Low Idle System........................................................................................................................... 130 Automatic Low Idle System Diagram............................................................................................................... 130 Function of Automatic Low Idle System........................................................................................................... 130 Operation of Automatic Low Idle System.......................................................................................................... 131 Engine Automatic Warm-up System..................................................................................................................... 132 System Diagram of Engine Automatic Warm-up System............................................................................................... 132 Function of Engine Automatic Warm-up System..................................................................................................... 133 Overheat Prevention System.......................................................................................................................... 134 Overheat Prevention System Diagram.............................................................................................................. 134 Function of Overheat Prevention System.......................................................................................................... 134 Turbocharger Protection System...................................................................................................................... 135 System Diagram of Turbocharger Protection System................................................................................................ 135 Function of Turbocharger Protection System...................................................................................................... 135 Automatic Idle Stop System.......................................................................................................................... 137 System Diagram of Automatic Idle Stop System.................................................................................................... 137 Function of Automatic Idle Stop System.......................................................................................................... 137 Component Parts of Engine System.................................................................................................................... 140 PTO............................................................................................................................................. 140 VGT............................................................................................................................................. 142 EGR System...................................................................................................................................... 146 EGR Valve....................................................................................................................................... 149 EGR Cooler...................................................................................................................................... 151 KCCV System..................................................................................................................................... 152 KCCV Ventilator................................................................................................................................. 154 KDPF............................................................................................................................................ 156 Cooling System.......................................................................................................................................... 160 Layout Drawing of Cooling System.................................................................................................................... 160 Specifications of Cooling System................................................................................................................ 161 Fan Speed Control System of Hydraulic Fan........................................................................................................... 162 Fan Speed Control System Diagram of Hydraulic Fan............................................................................................... 162 Function of Fan Speed Control System of Hydraulic Fan........................................................................................... 163 Engine Output Control System of Hydraulic Fan....................................................................................................... 164 Engine Output Control System Diagram of Hydraulic Fan........................................................................................... 164 Function of Engine Output Control System of Hydraulic Fan....................................................................................... 164 Fan Reverse Rotation System of Hydraulic Fan........................................................................................................ 166 Fan Reverse Rotation System Diagram of Hydraulic Fan............................................................................................ 166 Function of Fan Reverse Rotation System of Hydraulic Fan........................................................................................ 166 Component Parts of Cooling System................................................................................................................... 167 Cooling Fan Pump................................................................................................................................ 167 Cooling Fan Motor............................................................................................................................... 182 Control System.......................................................................................................................................... 189 Layout Drawing of Control System.................................................................................................................... 189 Machine Monitor System.............................................................................................................................. 191 System Diagram of Machine Monitor System........................................................................................................ 191 KomVision System.................................................................................................................................... 192 Layout Drawing of KomVision System.............................................................................................................. 192 System Diagram of KomVision System.............................................................................................................. 194 Function of KomVision System.................................................................................................................... 195 KOMTRAX Plus System................................................................................................................................. 197 System Diagram of KOMTRAX Plus System........................................................................................................... 197 Function of KOMTRAX Plus System................................................................................................................. 198 Component Parts of Control System................................................................................................................... 202 Machine Monitor................................................................................................................................. 202 KomVision Controller............................................................................................................................ 217 KomVision Camera................................................................................................................................ 221 KOMTRAX Terminal................................................................................................................................ 222 KOMTRAX Plus Controller......................................................................................................................... 224 Wireless LAN Unit............................................................................................................................... 229 Pump Controller................................................................................................................................. 230 Resistor for TVC Valve.......................................................................................................................... 235 CAN Terminating Resistor........................................................................................................................ 236 Engine Controller............................................................................................................................... 237 Fuel Control Dial............................................................................................................................... 251 Fuel Feed Pump.................................................................................................................................. 252 Fuel Feed Pump Switch........................................................................................................................... 253 Hydraulic System........................................................................................................................................ 254 Layout Drawing of Hydraulic System.................................................................................................................. 254 OLSS................................................................................................................................................ 257 Structure of OLSS............................................................................................................................... 257 Function of OLSS................................................................................................................................ 258 Pump Swash Plate Angle (Oil Flow) Control....................................................................................................... 259 Engine and Pump Combined Control System............................................................................................................. 270 Engine and Pump Combined Control System Diagram................................................................................................. 270 Function of Engine and Pump Combined Control System............................................................................................. 272 Component Parts of Hydraulic System................................................................................................................. 274 Hydraulic Tank.................................................................................................................................. 274 Main Pump....................................................................................................................................... 276 Control Valve................................................................................................................................... 320 Variable Back Pressure Valve.................................................................................................................... 343 Work Equipment System................................................................................................................................... 346 Layout Drawing of Work Equipment System............................................................................................................. 346 Machine Push-up System.............................................................................................................................. 352 Machine Push-up System Diagram.................................................................................................................. 352 Function of Machine Push-up System.............................................................................................................. 353 Heavy Lift System................................................................................................................................... 354 Heavy Lift System Diagram....................................................................................................................... 354 Function of Heavy Lift System................................................................................................................... 356 Operation of Heavy Lift System.................................................................................................................. 356 Boom Shockless Control System....................................................................................................................... 357 Boom Shockless Control Function System Diagram.................................................................................................. 357 Function of Boom Shockless Control System....................................................................................................... 357 Operation of Boom Shockless Control System...................................................................................................... 358 PPC Lock System..................................................................................................................................... 359 System Diagram of PPC Lock...................................................................................................................... 359 Function of PPC Lock System..................................................................................................................... 359 Work Equipment and Travel Automatic Lock System..................................................................................................... 360 System Diagram of Lock Lever Automatic Lock System.............................................................................................. 360 Function of Work Equipment and Travel Automatic Lock System..................................................................................... 360 Operation of Lock Lever Automatic Lock System................................................................................................... 361 Component Parts of Work Equipment System............................................................................................................ 362 Work Equipment and Swing PPC Valve.............................................................................................................. 362 Solenoid Valve.................................................................................................................................. 367 Pilot Circuit Accumulator....................................................................................................................... 373 Swing System............................................................................................................................................ 375 Layout Drawing of Swing System...................................................................................................................... 375 Swing Control System Diagram........................................................................................................................ 378 Function of Swing Control System................................................................................................................ 379 Swing Priority System Diagram....................................................................................................................... 382 Function of Swing Priority System............................................................................................................... 384 Swing Compensation System Diagram................................................................................................................... 385 Function of Swing Compensation System........................................................................................................... 385 Operation of Swing Compensation System.......................................................................................................... 385 Component Parts of Swing System..................................................................................................................... 386 Swing Motor..................................................................................................................................... 386 Swing Machinery................................................................................................................................. 398 Swing Circle.................................................................................................................................... 400 Travel System........................................................................................................................................... 401 Layout Drawing of Travel System..................................................................................................................... 401 System Diagram of Travel Control System............................................................................................................. 405 Function of Travel Control System............................................................................................................... 407 Component Parts of Travel System.................................................................................................................... 408 Travel Motor.................................................................................................................................... 408 Final Drive..................................................................................................................................... 419 Travel PPC Valve................................................................................................................................ 421 Center Swivel Joint............................................................................................................................. 425 Pneumatic System........................................................................................................................................ 427 Layout Drawing of Pneumatic System.................................................................................................................. 427 Pneumatic System Diagram............................................................................................................................ 428 Function of Pneumatic System.................................................................................................................... 428 Component Parts of Pneumatic System................................................................................................................. 429 Air Governor.................................................................................................................................... 429 Air Tank........................................................................................................................................ 430 Horn Valve...................................................................................................................................... 432 Grease Pump..................................................................................................................................... 433 Lifting System.......................................................................................................................................... 434 Hydraulically Operated Stairway System.............................................................................................................. 434 Layout Drawing of Hydraulically Operated Stairway System........................................................................................ 434 Hydraulically Operated Stairway System Diagram.................................................................................................. 435 Function of Hydraulically Operated Stairway System.............................................................................................. 436 Component Parts of Lifting System................................................................................................................... 437 Switch Box...................................................................................................................................... 437 Proximity Switch Part........................................................................................................................... 438 Control Valve Assembly.......................................................................................................................... 439 Undercarriage and Frame................................................................................................................................. 440 Layout Drawing of Undercarriage..................................................................................................................... 440 Specifications of Undercarriage................................................................................................................. 441 Work Equipment.......................................................................................................................................... 442 Structure of Work Equipment......................................................................................................................... 442 Function of Work Equipment.......................................................................................................................... 442 Work Equipment Clearance Adjustment Shim............................................................................................................ 443 Function of Work Equipment Clearance Adjustment Shim............................................................................................ 443 Bucket Clearance Adjustment Shim.................................................................................................................... 443 Function of Bucket Clearance Adjustment Shim.................................................................................................... 443 CAB Related Parts....................................................................................................................................... 444 CAB................................................................................................................................................. 444 Structure of CAB................................................................................................................................ 444 CAB Mount........................................................................................................................................... 445 Structure of CAB Mount.......................................................................................................................... 445 Function of CAB Mount........................................................................................................................... 445 CAB Tipping Stopper................................................................................................................................. 446 Structure of CAB Tipping Stopper................................................................................................................ 446 Function of CAB Tipping Stopper................................................................................................................. 446 20 Standard Value Table..................................................................................................................................... 447 Table of Contents....................................................................................................................................... 448 Standard Value Table for Engine......................................................................................................................... 449 Standard Value Table for Engine: PC1250-11.......................................................................................................... 449 Standard Value Table for Engine: PC1250SP-11........................................................................................................ 454 Standard Value Table for Machine........................................................................................................................ 459 Standard Value Table for Machine: PC1250-11......................................................................................................... 459 Standard Value Table for Machine: PC1250-11 (Loading Shovel Specification).......................................................................... 473 Standard Value Table for Machine: PC1250SP-11....................................................................................................... 488 Machine Posture and Procedures to Measure Performance............................................................................................... 502 Machine Posture and Procedures to Measure Performance (Loading Shovel Specification)................................................................ 506 30 Testing and Adjusting.................................................................................................................................... 511 Table of Contents....................................................................................................................................... 512 Precautions Before Work................................................................................................................................. 516 Related Information on Testing and Adjusting............................................................................................................ 517 Tools for Testing and Adjusting..................................................................................................................... 517 Sketch of Tools for Testing and Adjusting........................................................................................................... 524 Engine and Cooling System............................................................................................................................... 525 Examine Engine Speed................................................................................................................................ 525 How to Examine Engine Speed..................................................................................................................... 525 Examine Boost Pressure.............................................................................................................................. 528 How to Examine Boost Pressure on Machine Monitor................................................................................................ 528 How to Examine Boost Pressure by Testing Tool................................................................................................... 529 Examine Exhaust Gas Temperature..................................................................................................................... 530 How to Examine Exhaust Gas Temperature.......................................................................................................... 530 Examine Exhaust Gas Color........................................................................................................................... 532 How to Examine Exhaust Gas Color with the Handy Smoke Checker................................................................................... 532 How to Examine Exhaust Gas Color with Smoke Meter............................................................................................... 533 Examine Mass Air Flow and Temperature Sensor........................................................................................................ 536 How to Examine Mass Air Flow and Temperature Sensor............................................................................................. 536 Examine and Adjust Valve Clearance.................................................................................................................. 538 How to Examine Valve Clearance.................................................................................................................. 538 How to Adjust Valve Clearance................................................................................................................... 539 Examine Compression Pressure........................................................................................................................ 541 How to Examine Compression Pressure............................................................................................................. 541 Examine Blowby Pressure............................................................................................................................. 545 How to Examine Blowby Pressure.................................................................................................................. 545 Examine Engine Oil Pressure......................................................................................................................... 547 How to Examine Engine Oil Pressure on Machine Monitor........................................................................................... 547 How to Examine Engine Oil Pressure by Testing Tool.............................................................................................. 547 Examine EGR Valve and VGT Oil Pressure.............................................................................................................. 549 How to Examine EGR Valve and VGT Oil Pressure................................................................................................... 549 Examine Fuel Pressure............................................................................................................................... 550 How to Examine Fuel Pressure.................................................................................................................... 550 Examine Fuel Return Rate and Leakage................................................................................................................ 552 How to Examine Fuel Return Rate and Leakage..................................................................................................... 553 Bleed Air from Fuel System.......................................................................................................................... 557 How to Bleed Air from Fuel System............................................................................................................... 557 Examine Fuel Circuit for Leakage.................................................................................................................... 559 How to Examine Fuel System for Leakage.......................................................................................................... 559 Examine Supply Pump................................................................................................................................. 561 How to Examine Supply Pump...................................................................................................................... 561 Handle Cylinder Cut-out Mode Operation.............................................................................................................. 564 Examine Alternator.................................................................................................................................. 565 How to Examine Alternator....................................................................................................................... 565 Handle No-Injection Cranking Operation.............................................................................................................. 566 Clean Fuel Doser.................................................................................................................................... 567 How to Clean Fuel Doser......................................................................................................................... 567 Write Injector Compensation Value to Engine Controller.............................................................................................. 570 How to Write Injector Compensation Value........................................................................................................ 570 Write Correction for Ash in Soot Accumulation to Engine Controller.................................................................................. 576 How to Write Correction for Ash in Soot Accumulation to Engine Controller....................................................................... 576 Power Train............................................................................................................................................. 577 Examine Swing Circle Bearing Clearance.............................................................................................................. 577 How to Examine Swing Circle Bearing Clearance................................................................................................... 577 Undercarriage and Frame................................................................................................................................. 579 Examine Sprocket Wear............................................................................................................................... 579 How to Examine Sprocket Wear.................................................................................................................... 579 Examine and Adjust Track Tension.................................................................................................................... 580 How to Examine Track Tension.................................................................................................................... 580 How to Adjust Track Tension..................................................................................................................... 580 Hydraulic System........................................................................................................................................ 582 Release Remained Pressure in Hydraulic Circuit...................................................................................................... 582 How to Release Remained Pressure in Hydraulic System............................................................................................ 582 How to Release Remained Pressure from Swing Motor Circuit....................................................................................... 585 How to Release Remained Pressure from Travel Motor Circuit...................................................................................... 585 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits....................................................................... 587 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits....................................................................... 590 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits........................................................................ 597 Examine and Adjust Oil Pressure in Control Circuit.................................................................................................. 601 How to Examine Oil Pressure in Control Circuit.................................................................................................. 601 How to Adjust Oil Pressure in Control Circuit................................................................................................... 602 Examine and Adjust Piston Pump Control Oil Pressure................................................................................................. 603 How to Examine TVC Valve Outlet Pressure........................................................................................................ 603 How to Examine CO Valve + NC Valve Outlet Pressure of No. 1 and No. 2 Pumps..................................................................... 604 How to Examine CO Valve + NC Valve Outlet Pressure of No. 3 Pump................................................................................ 605 How to Examine Jet Sensor Outlet Differential Pressure of 4-Spool Control Valve on the Right Side and 5-Spool Control Valve on the Left Side.... 606 How to Examine Jet Sensor Outlet Differential Pressure of 4-Spool Control Valve for Swing....................................................... 607 How to Adjust TVC Valve......................................................................................................................... 608 How to Adjust CO Valve + NC Valve of No. 1 and No. 2 Pumps...................................................................................... 609 How to Adjust CO Valve + NC Valve of No. 3 Pump................................................................................................. 610 How to Adjust Jet Sensor of 4-Spool Control Valve on the Right Side and 5-Spool Control Valve on the Left Side.................................. 610 How to Adjust Jet Sensor of 4-Spool Control Valve for Swing..................................................................................... 611 Examine Servo Piston Stroke......................................................................................................................... 612 How to Examine Servo Piston Stroke.............................................................................................................. 612 Examine Outlet Pressure of Solenoid Valve........................................................................................................... 614 How to Examine Outlet Pressure of Solenoid Valve................................................................................................ 614 Operating Condition of Solenoid Valve........................................................................................................... 616 Examine PPC Valve Outlet Pressure................................................................................................................... 619 How to Examine Outlet Pressure in PPC Valve..................................................................................................... 619 Examine Swing PPC Shuttle Valve Outlet Pressure..................................................................................................... 621 How to Examine Swing PPC Shuttle Valve Outlet Pressure.......................................................................................... 621 Adjust Play of Work Equipment and Swing PPC Valves.................................................................................................. 623 How to Adjust Play of Work Equipment and Swing PPC Valves....................................................................................... 623 Examine Travel Deviation............................................................................................................................ 624 How to Examine Travel Deviation................................................................................................................. 624 Examine Cooling Fan Speed........................................................................................................................... 625 How to Examine Cooling Fan Speed................................................................................................................ 625 Examine Aftercooler Fan Speed....................................................................................................................... 626 How to Examine Aftercooler Fan Speed............................................................................................................ 626 Examine Oil Pressure in Fan Pump Circuit............................................................................................................ 627 How to Examine Oil Pressure in Fan Pump Circuit................................................................................................. 627 Examine Aftercooler Fan Pump Circuit Oil Pressure................................................................................................... 628 How to Examine Aftercooler Fan Pump Circuit Oil Pressure........................................................................................ 628 Examine Fan Pump EPC Electric Current............................................................................................................... 629 How to Examine Fan Pump EPC Electric Current.................................................................................................... 629 Examine Fan Pump EPC Solenoid Valve Outlet Pressure................................................................................................. 630 How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure...................................................................................... 630 Examine Parts Which Cause Hydraulic Drift of Work Equipment......................................................................................... 631 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder........................................................... 631 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder............................................................................ 631 How to Examine Parts that Cause Hydraulic Drift of PPC Valve.................................................................................... 632 Examine Oil Leakage................................................................................................................................. 633 How to Examine Oil Leakage from Boom Cylinder................................................................................................... 633 How to Examine Oil Leakage from Arm Cylinder.................................................................................................... 634 How to Examine Oil Leakage from Bucket Cylinder................................................................................................. 634 How to Examine Oil Leakage from Swing Motor..................................................................................................... 635 How to Examine Oil Leakage from Travel Motor.................................................................................................... 635 How to Examine Oil Leakage of Swivel Joint...................................................................................................... 636 Bleed Air from Hydraulic System..................................................................................................................... 638 How to Bleed Air from Hydraulic System.......................................................................................................... 639 CAB Related Parts....................................................................................................................................... 643 Examine CAB Tipping Stopper......................................................................................................................... 643 How to Examine Cab Tipping Stopper.............................................................................................................. 643 How to Adjust Mirrors............................................................................................................................... 644 Procedure to Adjust Machine Left Front Mirror (A)............................................................................................... 644 Procedure to Adjust Regular Position of Machine Left Front Mirror (A)........................................................................... 645 Procedure to Adjust Machine Right Front Mirror (B).............................................................................................. 646 Procedure to Adjust Regular Position of Machine Right Front Mirror (B).......................................................................... 647 Procedure to Adjust Machine Right Front Mirror (C).............................................................................................. 648 Procedure to Adjust Regular Position of Machine Right Front Mirror (C).......................................................................... 649 Electrical System....................................................................................................................................... 651 Set and Operate Machine Monitor..................................................................................................................... 651 Operator Mode................................................................................................................................... 655 Function to Show Technician Identification Status Screen........................................................................................ 655 Function to Show Operator Identification Input Screen........................................................................................... 655 Examine Function by LCD (Liquid Crystal Display)................................................................................................ 656 Examine Function of Service Meter............................................................................................................... 656 Usage Limitation and Maintenance Password Change Function....................................................................................... 656 Service Mode.................................................................................................................................... 659 How to Operate Service Mode..................................................................................................................... 659 How to See Pre-defined Monitoring Information................................................................................................... 661 How to Examine Self-Define Monitor Information.................................................................................................. 665 Abnormality Record Menu......................................................................................................................... 675 How to See Maintenance Record................................................................................................................... 679 Maintenance Mode Setting........................................................................................................................ 680 How to Set Phone Number Entry................................................................................................................... 684 Default Menu.................................................................................................................................... 686 Diagnostic Tests Menu........................................................................................................................... 694 Adjustment Menu................................................................................................................................. 704 No-Injection Cranking Operation................................................................................................................. 710 KOMTRAX Settings Menu........................................................................................................................... 712 How to Show Service Message..................................................................................................................... 714 How to Operate Snap Shot........................................................................................................................ 715 How to Start Up KOMTRAX Terminal.................................................................................................................... 717 Default Setting of KOMTRAX Plus Controller.......................................................................................................... 723 Default Setting of KOMTRAX Plus Controller...................................................................................................... 723 Default Setting of Wireless LAN Modem............................................................................................................... 726 Default Setting of Wireless LAN Modem........................................................................................................... 726 How to Examine Wireless LAN Modem Communication................................................................................................. 727 Download Data from KOMTRAX Plus Controller.......................................................................................................... 729 How to Download Data from KOMTRAX Plus Controller............................................................................................... 729 How to Download Data from Service Connector..................................................................................................... 731 How to Download Data from Wireless LAN (Wireless LAN Spec)...................................................................................... 732 Adjust After Replacement of KOMTRAX Plus Controller................................................................................................. 733 How to Adjust After Replacement of KOMTRAX Plus Controller...................................................................................... 733 Adjust After Replacement of Wireless LAN Modem...................................................................................................... 736 How to Adjust After Replacement of Wireless LAN Modem........................................................................................... 736 Adjust KomVision Camera Angle....................................................................................................................... 739 How to Adjust KomVision Camera Angle............................................................................................................ 740 Adjust KomVision Related Function................................................................................................................... 742 Setting of KomVision (Main Setting)............................................................................................................. 743 Setting of KomVision (Camera Setting)........................................................................................................... 745 Setting of KomVision (Camera Calibration)....................................................................................................... 748 KomVision screen - Check 12 m visibility........................................................................................................ 761 Handle Voltage Circuit of Engine Controller......................................................................................................... 764 Handle Battery Disconnect Switch.................................................................................................................... 765 Examine Diodes...................................................................................................................................... 766 How to Examine Diodes by Digital Tester......................................................................................................... 766 How to Examine Diodes by Analog Tester.......................................................................................................... 766 Pm Clinic............................................................................................................................................... 767 Pm Clinic Service................................................................................................................................... 767 Pm Clinic Check Sheet: PC1250-11................................................................................................................ 772 Pm Clinic Check Sheet: PC1250SP-11.............................................................................................................. 785 Perform Quick Pm.................................................................................................................................... 798 How to Perform Quick Pm......................................................................................................................... 798 40 Troubleshooting.......................................................................................................................................... 803 Table of Contents....................................................................................................................................... 804 Precautions Before Work................................................................................................................................. 815 Related Information to Troubleshooting.................................................................................................................. 816 General Troubleshooting Points...................................................................................................................... 816 Troubleshooting Points for Aftertreatment System.................................................................................................... 817 Sequence of Events in Troubleshooting............................................................................................................... 824 Checks Before Troubleshooting....................................................................................................................... 826 Inspection Procedure Before Troubleshooting......................................................................................................... 828 Walk-Around Check............................................................................................................................... 828 Test in Accordance with Testing Procedure........................................................................................................... 830 Examine Fuel Level and Type..................................................................................................................... 830 Examine for Impure Ingredient in Fuel........................................................................................................... 831 Examine Fuel Prefilter.......................................................................................................................... 831 Examine Water Separator, Drain Water and Sediment............................................................................................... 832 Replace Fuel Prefilter Cartridge................................................................................................................ 832 Examine Fuel Main Filter........................................................................................................................ 833 Examine Engine Oil Level (Oil Quantity in Oil Pan).............................................................................................. 835 Examine Coolant Level (Reservoir Tank).......................................................................................................... 836 Examine Air Cleaner Clogging.................................................................................................................... 837 Clean Outer Element............................................................................................................................. 837 Replace Element................................................................................................................................. 840 Examine Hydraulic Oil Level..................................................................................................................... 840 Examine Hydraulic Oil Strainer.................................................................................................................. 842 Examine Hydraulic Oil Filter.................................................................................................................... 843 Examine Oil Level in Swing Machinery Case....................................................................................................... 844 Examine Oil Level in PTO Case................................................................................................................... 846 Examine PTO Lubrication Filter Strainer......................................................................................................... 846 Examine Oil Level in Final Drive Case........................................................................................................... 847 Bleed Air from Fuel System...................................................................................................................... 847 Bleed Air from Hydraulic System................................................................................................................. 847 How to Examine Electric Equipment............................................................................................................... 847 Preparation for Troubleshooting of Electrical System................................................................................................ 853 Preparation for Troubleshooting of Machine Monitor.............................................................................................. 853 Preparation for Troubleshooting of Engine Controller............................................................................................ 853 Preparation for Troubleshooting of Pump Controller.............................................................................................. 853 Preparation for Troubleshooting of KOMTRAX Terminal............................................................................................. 854 Preparation for Troubleshooting of KOMTRAX Plus Controller...................................................................................... 854 Preparation for Troubleshooting of KomVision Controller......................................................................................... 854 How to Disconnect and Connect Connector with a Special Lock..................................................................................... 854 Procedure for Troubleshooting....................................................................................................................... 859 Symptom and Troubleshooting Numbers................................................................................................................. 862 Information Shown in Troubleshooting Table.......................................................................................................... 867 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness..................................................................... 869 Connector List and Layout........................................................................................................................... 872 Connector List and Layout (Loading Shovel Specification)............................................................................................ 888 Connector Contact Connection Table.................................................................................................................. 905 T-Branch Box and T-Branch Adapter Table............................................................................................................. 945 Fuse Location Table................................................................................................................................. 951 Precautions When You Clean and Replace KDPF (KCSF and KDOC)......................................................................................... 954 Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])....................................................... 958 Failure Code Table.................................................................................................................................. 960 Troubleshooting by Failure Code (Display of Code)....................................................................................................... 978 Failure Code [879AKA]............................................................................................................................... 978 Failure Code [879AKB]............................................................................................................................... 979 Failure Code [879BKA]............................................................................................................................... 980 Failure Code [879BKB]............................................................................................................................... 982 Failure Code [879CKA]............................................................................................................................... 984 Failure Code [879CKB]............................................................................................................................... 985 Failure Code [879DKZ]............................................................................................................................... 986 Failure Code [879EMC]............................................................................................................................... 988 Failure Code [879FMC]............................................................................................................................... 989 Failure Code [879GKX]............................................................................................................................... 990 Failure Code [8800ZG]............................................................................................................................... 992 Failure Code [989L00]............................................................................................................................... 993 Failure Code [989M00]............................................................................................................................... 994 Failure Code [989N00]............................................................................................................................... 995 Failure Code [A1U0N3]............................................................................................................................... 996 Failure Code [A1U0N4]............................................................................................................................... 998 Failure Code [AA10NX]...............................................................................................................................1000 Failure Code [AB00KE]...............................................................................................................................1002 Failure Code [AQ00N3]...............................................................................................................................1004 Failure Code [AQ00N4]...............................................................................................................................1005 Failure Code [AQ10N3]...............................................................................................................................1006 Failure Code [B@BAZG]...............................................................................................................................1007 Failure Code [B@BAZK]...............................................................................................................................1008 Failure Code [B@BCNS]...............................................................................................................................1010 Failure Code [B@BCZK]...............................................................................................................................1011 Failure Code [B@CBNS]...............................................................................................................................1013 Failure Code [B@HANS]...............................................................................................................................1015 Failure Code [CA115]................................................................................................................................1016 Failure Code [CA122]................................................................................................................................1020 Failure Code [CA123]................................................................................................................................1022 Failure Code [CA131]................................................................................................................................1024 Failure Code [CA132]................................................................................................................................1026 Failure Code [CA135]................................................................................................................................1028 Failure Code [CA141]................................................................................................................................1030 Failure Code [CA144]................................................................................................................................1032 Failure Code [CA145]................................................................................................................................1034 Failure Code [CA153]................................................................................................................................1036 Failure Code [CA154]................................................................................................................................1039 Failure Code [CA187]................................................................................................................................1041 Failure Code [CA212]................................................................................................................................1043 Failure Code [CA213]................................................................................................................................1045 Failure Code [CA221]................................................................................................................................1047 Failure Code [CA222]................................................................................................................................1049 Failure Code [CA227]................................................................................................................................1051 Failure Code [CA234]................................................................................................................................1053 Failure Code [CA238]................................................................................................................................1054 Failure Code [CA239]................................................................................................................................1056 Failure Code [CA271]................................................................................................................................1058 Failure Code [CA272]................................................................................................................................1060 Failure Code [CA273]................................................................................................................................1061 Failure Code [CA274]................................................................................................................................1063 Failure Code [CA322]................................................................................................................................1064 Failure Code [CA323]................................................................................................................................1066 Failure Code [CA324]................................................................................................................................1068 Failure Code [CA325]................................................................................................................................1070 Failure Code [CA331]................................................................................................................................1072 Failure Code [CA332]................................................................................................................................1074 Failure Code [CA343]................................................................................................................................1076 Failure Code [CA351]................................................................................................................................1078 Failure Code [CA352]................................................................................................................................1080 Failure Code [CA356]................................................................................................................................1082 Failure Code [CA357]................................................................................................................................1084 Failure Code [CA386]................................................................................................................................1086 Failure Code [CA441]................................................................................................................................1088 Failure Code [CA442]................................................................................................................................1090 Failure Code [CA449]................................................................................................................................1092 Failure Code [CA451]................................................................................................................................1093 Failure Code [CA452]................................................................................................................................1095 Failure Code [CA515]................................................................................................................................1097 Failure Code [CA516]................................................................................................................................1098 Failure Code [CA553]................................................................................................................................1099 Failure Code [CA555]................................................................................................................................1100 Failure Code [CA556]................................................................................................................................1102 Failure Code [CA559]................................................................................................................................1104 Failure Code [CA595]................................................................................................................................1109 Failure Code [CA687]................................................................................................................................1111 Failure Code [CA689]................................................................................................................................1113 Failure Code [CA691]................................................................................................................................1115 Failure Code [CA692]................................................................................................................................1117 Failure Code [CA697]................................................................................................................................1119 Failure Code [CA698]................................................................................................................................1120 Failure Code [CA731]................................................................................................................................1121 Failure Code [CA778]................................................................................................................................1125 Failure Code [CA1117]...............................................................................................................................1127 Failure Code [CA1135]...............................................................................................................................1129 Failure Code [CA1257]...............................................................................................................................1132 Failure Code [CA1664]...............................................................................................................................1133 Failure Code [CA1691]...............................................................................................................................1135 Failure Code [CA1695]...............................................................................................................................1138 Failure Code [CA1696]...............................................................................................................................1140 Failure Code [CA1843]...............................................................................................................................1142 Failure Code [CA1844]...............................................................................................................................1144 Failure Code [CA1879]...............................................................................................................................1146 Failure Code [CA1881]...............................................................................................................................1148 Failure Code [CA1883]...............................................................................................................................1150 Failure Code [CA1921]...............................................................................................................................1153 Failure Code [CA1922]...............................................................................................................................1155 Failure Code [CA1923]...............................................................................................................................1159 Failure Code [CA1924]...............................................................................................................................1161 Failure Code [CA1925]...............................................................................................................................1163 Failure Code [CA1927]...............................................................................................................................1165 Failure Code [CA1928]...............................................................................................................................1167 Failure Code [CA1942]...............................................................................................................................1169 Failure Code [CA1963]...............................................................................................................................1171 Failure Code [CA1977]...............................................................................................................................1175 Failure Code [CA1993]...............................................................................................................................1177 Failure Code [CA2185]...............................................................................................................................1179 Failure Code [CA2186]...............................................................................................................................1180 Failure Code [CA2249]...............................................................................................................................1182 Failure Code [CA2265]...............................................................................................................................1187 Failure Code [CA2266]...............................................................................................................................1189 Failure Code [CA2271]...............................................................................................................................1191 Failure Code [CA2272]...............................................................................................................................1193 Failure Code [CA2349]...............................................................................................................................1195 Failure Code [CA2353]...............................................................................................................................1197 Failure Code [CA2357]...............................................................................................................................1199 Failure Code [CA2381]...............................................................................................................................1202 Failure Code [CA2382]...............................................................................................................................1204 Failure Code [CA2383]...............................................................................................................................1206 Failure Code [CA2386]...............................................................................................................................1208 Failure Code [CA2387]...............................................................................................................................1210 Troubleshooting Flowchart.......................................................................................................................1214 Failure Code [CA2555]...............................................................................................................................1215 Failure Code [CA2556]...............................................................................................................................1217 Failure Code [CA2637]...............................................................................................................................1219 Failure Code [CA2639]...............................................................................................................................1222 Failure Code [CA2732]...............................................................................................................................1224 Failure Code [CA2733]...............................................................................................................................1226 Failure Code [CA2741]...............................................................................................................................1228 Failure Code [CA2765]...............................................................................................................................1229 Failure Code [CA2777]...............................................................................................................................1230 Failure Code [CA2878]...............................................................................................................................1232 Failure Code [CA2881]...............................................................................................................................1235 Failure Code [CA3133]...............................................................................................................................1238 Failure Code [CA3134]...............................................................................................................................1240 Failure Code [CA3135]...............................................................................................................................1242 Failure Code [CA3167]...............................................................................................................................1245 Failure Code [CA3251]...............................................................................................................................1248 Failure Code [CA3253]...............................................................................................................................1250 Failure Code [CA3254]...............................................................................................................................1254 Failure Code [CA3255]...............................................................................................................................1257 Failure Code [CA3256]...............................................................................................................................1260 Failure Code [CA3311]...............................................................................................................................1262 Failure Code [CA3312]...............................................................................................................................1264 Failure Code [CA3313]...............................................................................................................................1266 Failure Code [CA3314]...............................................................................................................................1267 Failure Code [CA3315]...............................................................................................................................1268 Failure Code [CA3316]...............................................................................................................................1271 Failure Code [CA3317]...............................................................................................................................1272 Failure Code [CA3318]...............................................................................................................................1273 Failure Code [CA3319]...............................................................................................................................1276 Failure Code [CA3321]...............................................................................................................................1277 Failure Code [CA3322]...............................................................................................................................1278 Failure Code [CA3419]...............................................................................................................................1281 Failure Code [CA3421]...............................................................................................................................1283 Failure Code [CA4151]...............................................................................................................................1285 Failure Code [CA4158]...............................................................................................................................1288 Failure Code [CA4161]...............................................................................................................................1289 Failure Code [CA4162]...............................................................................................................................1291 Failure Code [CA4163]...............................................................................................................................1293 Failure Code [CA4259]...............................................................................................................................1295 Failure Code [CA4952]...............................................................................................................................1297 Failure Code [CA5383]...............................................................................................................................1299 Failure Code [CB115]................................................................................................................................1300 Failure Code [CB187]................................................................................................................................1303 Failure Code [CB227]................................................................................................................................1305 Failure Code [CB238]................................................................................................................................1306 Failure Code [CB239]................................................................................................................................1308 Failure Code [CB271]................................................................................................................................1310 Failure Code [CB272]................................................................................................................................1312 Failure Code [CB273]................................................................................................................................1313 Failure Code [CB274]................................................................................................................................1315 Failure Code [CB343]................................................................................................................................1316 Failure Code [CB352]................................................................................................................................1318 Failure Code [CB386]................................................................................................................................1320 Failure Code [CB441]................................................................................................................................1322 Failure Code [CB442]................................................................................................................................1324 Failure Code [CB689]................................................................................................................................1326 Failure Code [CB697]................................................................................................................................1328 Failure Code [CB698]................................................................................................................................1329 Failure Code [CB731]................................................................................................................................1330 Failure Code [CB778]................................................................................................................................1334 Failure Code [CB1117]...............................................................................................................................1336 Failure Code [CB1257]...............................................................................................................................1338 Failure Code [CB1664]...............................................................................................................................1339 Failure Code [CB1691]...............................................................................................................................1341 Failure Code [CB1695]...............................................................................................................................1344 Failure Code [CB1696]...............................................................................................................................1346 Failure Code [CB1879]...............................................................................................................................1348 Failure Code [CB1881]...............................................................................................................................1350 Failure Code [CB1883]...............................................................................................................................1352 Failure Code [CB1921]...............................................................................................................................1355 Failure Code [CB1922]...............................................................................................................................1357 Failure Code [CB1923]...............................................................................................................................1361 Failure Code [CB1924]...............................................................................................................................1363 Failure Code [CB1925]...............................................................................................................................1365 Failure Code [CB1927]...............................................................................................................................1367 Failure Code [CB1928]...............................................................................................................................1369 Failure Code [CB1963]...............................................................................................................................1371 Failure Code [CB1977]...............................................................................................................................1375 Failure Code [CB1993]...............................................................................................................................1377 Failure Code [CB2265]...............................................................................................................................1379 Failure Code [CB2266]...............................................................................................................................1381 Failure Code [CB2637]...............................................................................................................................1383 Failure Code [CB2639]...............................................................................................................................1386 Failure Code [CB2732]...............................................................................................................................1388 Failure Code [CB2733]...............................................................................................................................1390 Failure Code [CB2741]...............................................................................................................................1392 Failure Code [CB2777]...............................................................................................................................1394 Failure Code [CB2878]...............................................................................................................................1396 Failure Code [CB2881]...............................................................................................................................1399 Failure Code [CB3133]...............................................................................................................................1402 Failure Code [CB3134]...............................................................................................................................1404 Failure Code [CB3135]...............................................................................................................................1406 Failure Code [CB3167]...............................................................................................................................1409 Failure Code [CB3251]...............................................................................................................................1412 Failure Code [CB3253]...............................................................................................................................1414 Failure Code [CB3254]...............................................................................................................................1419 Failure Code [CB3255]...............................................................................................................................1422 Failure Code [CB3256]...............................................................................................................................1425 Failure Code [CB3311]...............................................................................................................................1427 Failure Code [CB3312]...............................................................................................................................1429 Failure Code [CB3313]...............................................................................................................................1431 Failure Code [CB3314]...............................................................................................................................1432 Failure Code [CB3315]...............................................................................................................................1433 Failure Code [CB3316]...............................................................................................................................1436 Failure Code [CB3317]...............................................................................................................................1437 Failure Code [CB3318]...............................................................................................................................1438 Failure Code [CB3319]...............................................................................................................................1441 Failure Code [CB3321]...............................................................................................................................1442 Failure Code [CB3322]...............................................................................................................................1443 Failure Code [CB4151]...............................................................................................................................1446 Failure Code [CB4158]...............................................................................................................................1449 Failure Code [CB4161]...............................................................................................................................1450 Failure Code [CB4162]...............................................................................................................................1452 Failure Code [CB4163]...............................................................................................................................1454 Failure Code [CB4259]...............................................................................................................................1456 Failure Code [CB4952]...............................................................................................................................1458 Failure Code [CB5383]...............................................................................................................................1460 Failure Code [D110KB]...............................................................................................................................1461 Failure Code [D163KB]...............................................................................................................................1463 Failure Code [D195KA]...............................................................................................................................1465 Failure Code [D195KB]...............................................................................................................................1467 Failure Code [D19JKZ]...............................................................................................................................1469 Failure Code [D862KA]...............................................................................................................................1471 Failure Code [D8AQKR]...............................................................................................................................1473 Failure Code [DA20MC]...............................................................................................................................1477 Failure Code [DA22KK]...............................................................................................................................1478 Failure Code [DA25KP]...............................................................................................................................1480 Failure Code [DA26KP]...............................................................................................................................1482 Failure Code [DA29KQ]...............................................................................................................................1484 Failure Code [DA2LKA]...............................................................................................................................1486 Failure Code [DA2LKB]...............................................................................................................................1488 Failure Code [DA2QKR]...............................................................................................................................1490 Failure Code [DA2RKR]...............................................................................................................................1495 Failure Code [DAF0KM]...............................................................................................................................1500 Failure Code [DAF0MB]...............................................................................................................................1501 Failure Code [DAF0MC]...............................................................................................................................1502 Failure Code [DAF9KQ]...............................................................................................................................1503 Failure Code [DAFGMC]...............................................................................................................................1504 Failure Code [DAFLKA]...............................................................................................................................1505 Failure Code [DAFLKB]...............................................................................................................................1508 Failure Code [DAFQKR]...............................................................................................................................1510 Failure Code [DAZ9KQ]...............................................................................................................................1515 Failure Code [DAZQKR]...............................................................................................................................1516 Failure Code [DB2QKR]...............................................................................................................................1519 Failure Code [DB2RKR]...............................................................................................................................1526 Failure Code [DBP0KM]...............................................................................................................................1532 Failure Code [DBP0KT]...............................................................................................................................1533 Failure Code [DBP5KB]...............................................................................................................................1534 Failure Code [DBP5KY]...............................................................................................................................1536 Failure Code [DBPQKR]...............................................................................................................................1538 Failure Code [DBV0MC]...............................................................................................................................1543 Failure Code [DBV1KK]...............................................................................................................................1544 Failure Code [DBV5KB]...............................................................................................................................1546 Failure Code [DBV6KB]...............................................................................................................................1550 Failure Code [DBVLKA]...............................................................................................................................1552 Failure Code [DBVLKB]...............................................................................................................................1554 Failure Code [DBVQKR]...............................................................................................................................1556 Failure Code [DBVRKR]...............................................................................................................................1560 Failure Code [DBVVKR]...............................................................................................................................1564 Failure Code [DBVWKR]...............................................................................................................................1565 Failure Code [DDNRKA]...............................................................................................................................1566 Failure Code [DDNRKY]...............................................................................................................................1568 Failure Code [DDNS00]...............................................................................................................................1570 Failure Code [DGE5KB]...............................................................................................................................1572 Failure Code [DGH2KA]...............................................................................................................................1573 Failure Code [DGH2KB]...............................................................................................................................1575 Failure Code [DGT3KB]...............................................................................................................................1577 Failure Code [DGT4KA]...............................................................................................................................1579 Failure Code [DGT4KB]...............................................................................................................................1581 Failure Code [DHA4KA]...............................................................................................................................1583 Failure Code [DHAAMA]...............................................................................................................................1585 Failure Code [DHABMA]...............................................................................................................................1586 Failure Code [DHACMA]...............................................................................................................................1587 Failure Code [DHADMA]...............................................................................................................................1588 Failure Code [DHPAMA]...............................................................................................................................1589 Failure Code [DHPAZL]...............................................................................................................................1591 Failure Code [DHPBMA]...............................................................................................................................1592 Failure Code [DHPBZL]...............................................................................................................................1594 Failure Code [DHPGMA]...............................................................................................................................1595 Failure Code [DHPGZL]...............................................................................................................................1597 Failure Code [DHPSMA]...............................................................................................................................1598 Failure Code [DHPTKA]...............................................................................................................................1600 Failure Code [DHPTKB]...............................................................................................................................1602 Failure Code [DHS3MA]...............................................................................................................................1604 Failure Code [DHS4MA]...............................................................................................................................1607 Failure Code [DHS8MA]...............................................................................................................................1610 Failure Code [DHS9MA]...............................................................................................................................1613 Failure Code [DHSAMA]...............................................................................................................................1616 Failure Code [DHSBMA]...............................................................................................................................1619 Failure Code [DHSCMA]...............................................................................................................................1622 Failure Code [DHSDMA]...............................................................................................................................1625 Failure Code [DHSFMA]...............................................................................................................................1628 Failure Code [DHSGMA]...............................................................................................................................1631 Failure Code [DHSHMA]...............................................................................................................................1634 Failure Code [DHSJMA]...............................................................................................................................1637 Failure Code [DKR2KA]...............................................................................................................................1640 Failure Code [DKR2KB]...............................................................................................................................1642 Failure Code [DKR2NX]...............................................................................................................................1644 Failure Code [DKR3KA]...............................................................................................................................1646 Failure Code [DKR3KB]...............................................................................................................................1648 Failure Code [DKR3NX]...............................................................................................................................1650 Failure Code [DKULKA]...............................................................................................................................1652 Failure Code [DKULKB]...............................................................................................................................1654 Failure Code [DKULKY]...............................................................................................................................1656 Failure Code [DLM3KA]...............................................................................................................................1658 Failure Code [DLM3KB]...............................................................................................................................1660 Failure Code [DLM3MB]...............................................................................................................................1662 Failure Code [DR10KA]...............................................................................................................................1663 Failure Code [DR12KA]...............................................................................................................................1666 Failure Code [DR20KA]...............................................................................................................................1668 Failure Code [DR21KX]...............................................................................................................................1670 Failure Code [DR30KA]...............................................................................................................................1672 Failure Code [DR31KX]...............................................................................................................................1674 Failure Code [DR40KA]...............................................................................................................................1676 Failure Code [DUMBKA]...............................................................................................................................1678 Failure Code [DUMBKB]...............................................................................................................................1681 Failure Code [DV20KB]...............................................................................................................................1683 Failure Code [DW41KA]...............................................................................................................................1685 Failure Code [DW41KB]...............................................................................................................................1687 Failure Code [DW41KY]...............................................................................................................................1689 Failure Code [DW43KA]...............................................................................................................................1690 Failure Code [DW43KB]...............................................................................................................................1692 Failure Code [DW43KY]...............................................................................................................................1693 Failure Code [DW45KA]...............................................................................................................................1694 Failure Code [DW45KB]...............................................................................................................................1697 Failure Code [DW45KY]...............................................................................................................................1700 Failure Code [DW48KA]...............................................................................................................................1702 Failure Code [DW48KB]...............................................................................................................................1704 Failure Code [DW48KY]...............................................................................................................................1706 Failure Code [DW4CKY]...............................................................................................................................1707 Failure Code [DW7BKA]...............................................................................................................................1709 Failure Code [DW7BKB]...............................................................................................................................1711 Failure Code [DW7BKY]...............................................................................................................................1713 Failure Code [DW91KA]...............................................................................................................................1714 Failure Code [DW91KB]...............................................................................................................................1716 Failure Code [DW91KY]...............................................................................................................................1717 Failure Code [DWA5KA]...............................................................................................................................1718 Failure Code [DWA5KB]...............................................................................................................................1720 Failure Code [DWA5KY]...............................................................................................................................1722 Failure Code [DWK0KA]...............................................................................................................................1724 Failure Code [DWK0KB]...............................................................................................................................1726 Failure Code [DWK0KY]...............................................................................................................................1728 Failure Code [DWK2KA]...............................................................................................................................1729 Failure Code [DWK2KB]...............................................................................................................................1731 Failure Code [DWK2KY]...............................................................................................................................1733 Failure Code [DWK8KA]...............................................................................................................................1734 Failure Code [DWK8KB]...............................................................................................................................1736 Failure Code [DWK8KY]...............................................................................................................................1738 Failure Code [DX16KA]...............................................................................................................................1739 Failure Code [DX16KB]...............................................................................................................................1741 Failure Code [DXA0KA]...............................................................................................................................1743 Failure Code [DXA0KB]...............................................................................................................................1745 Failure Code [DXAXKA]...............................................................................................................................1747 Failure Code [DXAXKB]...............................................................................................................................1749 Failure Code [DY20KA]...............................................................................................................................1751 Failure Code [DY20KA]...............................................................................................................................1753 Failure Code [DY20MA]...............................................................................................................................1756 Failure Code [DY20MA]...............................................................................................................................1758 Failure Code [DY2CKB]...............................................................................................................................1761 Failure Code [DY2DKB]...............................................................................................................................1763 Failure Code [DY2DKB]...............................................................................................................................1765 Failure Code [DY2EKB]...............................................................................................................................1768 Failure Code [DY2EKB]...............................................................................................................................1770 Failure Code [DY2FMA]...............................................................................................................................1773 Failure Code [DY2GKM]...............................................................................................................................1775 Failure Code [F@BYNR]...............................................................................................................................1777 Failure Code [F@BYNS]...............................................................................................................................1778 Failure Code [J100KA]...............................................................................................................................1779 Failure Code [J100KB]...............................................................................................................................1781 Failure Code [J100L6]...............................................................................................................................1783 Failure Code [J190KA]...............................................................................................................................1784 Failure Code [J190KB]...............................................................................................................................1786 Failure Code [J190L6]...............................................................................................................................1788 Failure Code [LA10ZL]...............................................................................................................................1789 Troubleshooting of Electrical System (E-Mode)...........................................................................................................1790 E-1 Engine Does Not Start (Engine Does Not Crank)...................................................................................................1790 E-2 Manual Preheating System Does Not Operate.......................................................................................................1797 E-3 Automatic Preheating System Does Not Operate....................................................................................................1800 E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On...........................................................................1802 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing....................................................................1804 E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow...............................1807 E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow.........................1808 E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation........................................................................1809 E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs...........................................................................1810 E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs..............................................................................1811 E-11 Charge Level Monitor Comes On in Red While Engine is in Operation..............................................................................1812 E-12 Fuel Level Monitor Comes On in Red While Engine Runs...........................................................................................1813 E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation................................................................1814 E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation.......................................................................1815 E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation.................................................................1816 E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum.......................................................................................1817 E-17 Display of Fuel Gauge is Different from Actual Fuel Level......................................................................................1819 E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum........................................................................1820 E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..............................................................1821 E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum..................................................................1822 E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature............................................................1824 E-22 Some Areas of Machine Monitor Screen are Not Shown.............................................................................................1825 E-23 Function Switch Does Not Operate...............................................................................................................1826 E-24 Automatic Warm-up System Does Not Work (in Cold Weather).......................................................................................1827 E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out.........................................1828 E-26 Auto-Decelerator is Not Operated or Canceled with Lever........................................................................................1829 E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown...............................................................1830 E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed..............................................................1831 E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change.....................................................................1832 E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change....................................................................1833 E-31 Alarm Buzzer Cannot be Canceled................................................................................................................1834 E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position...........................................................................1835 E-33 Service Mode Cannot be Selected................................................................................................................1836 E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move.................................................................................1837 E-35 All Work Equipment, Swing and Travel Do Not Lock...............................................................................................1840 E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing.................................................................1842 E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate.................................................1845 E-38 Alarm Does Not Sound During Travel.............................................................................................................1847 E-39 Travel Alarm Does Not Stop When Machine Stops..................................................................................................1849 E-40 Horn Does Not Sound............................................................................................................................1850 E-41 Horn Does Not Stop.............................................................................................................................1853 E-42 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out........................................................................1855 E-43 Wiper Does Not Operate When Wiper Switch is Operated (Single Wiper Specification)..............................................................1856 E-44 Wiper Does Not Operate When Wiper Switch is Operated (Double Wiper Specification)..............................................................1858 E-45 Fuel Feed Pump Does Not Operate or Stop Automatically..........................................................................................1860 E-46 Window Washer Does Not Operate When Window Washer Switch is Operated...........................................................................1863 E-47 "Boom RAISE" is Not Shown Correctly with Monitoring Function...................................................................................1864 E-48 "Boom LOWER" is Not Shown Correctly with Monitoring Function...................................................................................1865 E-49 "Arm OUT" is Not Shown Correctly with Monitoring Function......................................................................................1866 E-50 "Arm IN" is Not Shown Correctly with Monitoring Function.......................................................................................1867 E-51 "Bucket DUMP" is Not Shown Correctly with Monitoring Function..................................................................................1868 E-52 "Bucket CURL" is Not Shown Correctly with Monitoring Function..................................................................................1869 E-53 "Swing" is Not Shown Correctly with Monitoring Function........................................................................................1870 E-54 "Travel" is Not Shown Correctly with Monitoring Function.......................................................................................1871 E-55 KOMTRAX System Does Not Operate Correctly......................................................................................................1872 E-56 Machine Push-Up Function Cannot be Canceled....................................................................................................1873 E-57 Machine Push-Up Function Does Not Operate......................................................................................................1875 E-58 Step Light Does Not Come On....................................................................................................................1876 E-59 Step Light Does Not Go Out.....................................................................................................................1879 E-60 Boom Shockless Function Cannot be Canceled.....................................................................................................1881 E-61 Boom Shockless Function Does Not Work..........................................................................................................1883 E-62 Bottom Dump Cannot be Operated.................................................................................................................1884 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)...........................................................................................1887 H-1 All Work Equipment, Travel, and Swing Speed or Power is Low.....................................................................................1887 H-2 Engine Speed Drops Significantly or Engine Stalls...............................................................................................1889 H-3 All Work Equipment, Swing and Travel Do Not Work................................................................................................1890 H-4 Unusual Noise is Heard from Around Work Equipment Pump..........................................................................................1892 H-5 Boom Speed or Power is Low in Normal Mode.......................................................................................................1893 H-6 Boom RAISE Speed or Power is Low in Heavy Lift Mode.............................................................................................1894 H-7 Boom LOWER Speed or Power is Low in Machine Push Up Mode........................................................................................1895 H-8 Arm Speed or Power is Low.......................................................................................................................1896 H-9 Bucket Speed or Power is Low....................................................................................................................1897 H-10 Boom Does Not Operate..........................................................................................................................1898 H-11 Arm Does Not Operate...........................................................................................................................1899 H-12 Bucket Does Not Operate........................................................................................................................1900 H-13 Hydraulic Drift of Boom is Large...............................................................................................................1901 H-14 Hydraulic Drift of Arm is Large................................................................................................................1902 H-15 Hydraulic Drift of Bucket is Large.............................................................................................................1903 H-16 Time Lag of Boom is Large......................................................................................................................1904 H-17 Time Lag of Arm is Large.......................................................................................................................1905 H-18 Time Lag of Bucket is Large....................................................................................................................1906 H-19 Boom Shockless Function Does Not Work or Cannot be Released....................................................................................1907 H-20 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Same Direction When Traveling Forward and Reverse)................1908 H-21 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Different Directions When Traveling Forward and Reverse)..........1910 H-22 Travel Deviation is Large at Start of Travel Only When Travel Lever is Fully Moved.............................................................1911 H-23 Regardless of the Stroke of the Travel Lever, Travel Deviation is Large at Start of Traveling..................................................1912 H-24 Travel Deviation is Large at Mixed Operation...................................................................................................1913 H-25 Travel Speed or Power is Low...................................................................................................................1914 H-26 Only the One Side Track Can Operate (Machine Does Not Travel FORWARD or REVERSE)...............................................................1915 H-27 Only the One Side Track Can Operate (in Either Forward or Reverse Direction)...................................................................1916 H-28 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast..............................................................................1917 H-29 Upper Structure Does Not Swing to Right and Left...............................................................................................1918 H-30 Upper Structure Swings Only to Right or Left...................................................................................................1919 H-31 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left)................................................................1920 H-32 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction..................................................1921 H-33 In Mixed Operation of Work Equipment, Swing Speed or Power is Low..............................................................................1922 H-34 Swing Acceleration or Swing Speed is Low During Mixed Operation with Boom in Swing Priority Mode...............................................1923 H-35 Upper Structure Overruns Too Much When It Stops Swing Operation in Lateral Directions of Right and Left........................................1924 H-36 Upper Structure Speed is High When It Stops Swing Operation (on One Side)......................................................................1925 H-37 Shock is Large When Upper Structure Stops Swing Operation (Right and Left).....................................................................1926 H-38 Shock is Large When Upper Structure Stops Swing Operation (in Only Right of Left Direction)....................................................1927 H-39 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation (in Right and Left Directions).........................................1928 H-40 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation in Only One Direction..................................................1929 H-41 Swing Drift on a Slope is Large................................................................................................................1930 H-42 Fan Rotation is Abnormal (Such as Excessive Noise or Vibration of Fan, or Overheating).........................................................1931 H-43 Bottom Dump Cannot be Moved....................................................................................................................1932 Troubleshooting of Engine (S-Mode)......................................................................................................................1933 Information Shown in Troubleshooting Table (S-Mode).................................................................................................1933 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position..........................................................................1934 S-2 Engine Cranks but No Exhaust Smoke Comes Out....................................................................................................1935 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)........................................................1936 S-4 Engine Startability is Unsatisfactory...........................................................................................................1937 S-5 Engine Does Not Pick Up Smoothly................................................................................................................1939 S-6 Engine Stops During Operation...................................................................................................................1941 S-7 Engine Runs Rough or is Not Stable..............................................................................................................1943 S-8 Engine Lacks Power..............................................................................................................................1944 S-9 KDPF Becomes Clogged in a Short Time............................................................................................................1946 S-10 Engine Oil Consumption is Excessive............................................................................................................1948 S-11 Oil Becomes Dirty Quickly......................................................................................................................1949 S-12 Fuel Consumption is Excessive..................................................................................................................1950 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant...........................................................................................1951 S-14 Oil Pressure Drops.............................................................................................................................1952 S-15 Fuel Mixes Into Engine Oil.....................................................................................................................1954 S-16 Water Mixes Into Engine Oil (Milky)............................................................................................................1955 S-17 Coolant Temperature Increases Too High (Overheating)...........................................................................................1956 S-18 Unusual Noise is Heard.........................................................................................................................1958 S-19 Vibration is Excessive.........................................................................................................................1959 S-20 Air Cannot be Bled from Fuel Circuit...........................................................................................................1960 S-21 Active Regeneration is Done Frequently.........................................................................................................1961 S-22 Active Regeneration Continues Long.............................................................................................................1962 S-23 White Smoke is Exhausted During Active Regeneration............................................................................................1963 50 Disassembly and Assembly.................................................................................................................................1965 Table of Contents.......................................................................................................................................1966 Precautions Before Work.................................................................................................................................1971 Related Information on Disassembly and Assembly.........................................................................................................1972 How to Read This Manual.............................................................................................................................1972 Coating Materials List..............................................................................................................................1974 Special Tool List...................................................................................................................................1979 Sketches of Special Tools...........................................................................................................................1998 Engine and Cooling System...............................................................................................................................2005 Remove and Install Supply Pump Assembly.............................................................................................................2005 How to Remove Supply Pump Assembly..............................................................................................................2005 How to Install Supply Pump Assembly.............................................................................................................2017 Remove and Install Injector Assembly................................................................................................................2031 How to Remove Injector Assembly.................................................................................................................2032 How to Install Injector Assembly................................................................................................................2042 Remove and Install Fuel Doser Assembly..............................................................................................................2055 How to Remove Fuel Doser Assembly...............................................................................................................2055 How to Install Fuel Doser Assembly..............................................................................................................2058 Remove and Install Cylinder Head Assembly...........................................................................................................2061 How to Remove Cylinder Head Assembly............................................................................................................2062 How to Install Cylinder Head Assembly...........................................................................................................2101 Remove and Install EGR Valve Assembly...............................................................................................................2152 How to Remove EGR Valve Assembly................................................................................................................2152 How to Install EGR Valve Assembly...............................................................................................................2156 Remove and Install EGR Cooler Assembly..............................................................................................................2160 How to Remove EGR Cooler Assembly...............................................................................................................2160 How to Install EGR Cooler Assembly..............................................................................................................2166 Remove and Install Starter Assembly.................................................................................................................2175 How to Remove Starting Motor Assembly...........................................................................................................2175 How to Install Starting Motor Assembly..........................................................................................................2175 Remove and Install Alternator Belt..................................................................................................................2177 How to Remove Alternator Belt...................................................................................................................2177 How to Install Alternator Belt..................................................................................................................2178 Remove and Install Radiator Assembly................................................................................................................2180 How to Remove Radiator Assembly.................................................................................................................2180 How to Install Radiator Assembly................................................................................................................2184 Remove and Install Hydraulic Oil Cooler Assembly....................................................................................................2189 How to Remove Hydraulic Oil Cooler Assembly.....................................................................................................2189 How to Install Hydraulic Oil Cooler Assembly....................................................................................................2194 Remove and Install Aftercooler Assembly.............................................................................................................2200 How to Remove Aftercooler Assembly..............................................................................................................2200 How to Install Aftercooler Assembly.............................................................................................................2206 Remove and Install Cooling Fan Motor Assembly.......................................................................................................2212 How to Remove Cooling Fan Motor Assembly........................................................................................................2212 How to Install Cooling Fan Motor Assembly.......................................................................................................2225 Remove and Install Engine, PTO, and Hydraulic Pump Assembly.........................................................................................2237 How to Remove Engine PTO and Hydraulic Assembly.................................................................................................2237 How to Install Engine PTO and Hydraulic Assembly................................................................................................2253 Remove and Install Engine Front Oil Seal............................................................................................................2269 How to Remove Engine Front Oil Seal.............................................................................................................2269 How to Install Engine Front Oil Seal............................................................................................................2272 Remove and Install Engine Rear Oil Seal.............................................................................................................2276 How to Remove Engine Rear Oil Seal..............................................................................................................2276 How to Install Engine Rear Oil Seal.............................................................................................................2277 Remove and Install Fuel Cooler Assembly.............................................................................................................2281 How to Remove Fuel Cooler Assembly..............................................................................................................2281 How to Install Fuel Cooler Assembly.............................................................................................................2282 Remove and Install Engine Hood Assembly.............................................................................................................2284 How to Remove Engine Hood Assembly..............................................................................................................2284 How to Install Engine Hood Assembly.............................................................................................................2290 Remove and Install Fuel Tank Assembly...............................................................................................................2297 How to Remove Fuel Tank Assembly................................................................................................................2297 How to Install Fuel Tank Assembly...............................................................................................................2302 Remove and Install KDPF Assembly....................................................................................................................2307 How to Remove KDPF Assembly.....................................................................................................................2307 How to Install KDPF Assembly....................................................................................................................2313 Disassemble and Assemble KDPF Assembly..............................................................................................................2320 How to Disassemble KDPF Assembly................................................................................................................2321 How to Assemble KDPF Assembly...................................................................................................................2326 Remove and Install Bellows Pipe Assembly............................................................................................................2334 How to Remove Bellows Pipe Assembly.............................................................................................................2334 How to Install Bellows Pipe Assembly............................................................................................................2338 Remove and Install KCCV Assembly....................................................................................................................2342 How to Remove KCCV Assembly.....................................................................................................................2342 How to Install KCCV Assembly....................................................................................................................2344 Remove and Install Air Cleaner Assembly.............................................................................................................2346 How to Remove Air Cleaner Assembly..............................................................................................................2346 How to Install Air Cleaner Assembly.............................................................................................................2346 Remove and Install Air Conditioner Compressor Assembly..............................................................................................2348 How to Remove Air Conditioner Compressor Assembly...............................................................................................2348 How to Install Air Conditioner Compressor Assembly..............................................................................................2349 Remove and Install Air Conditioner Condenser Assembly...............................................................................................2351 How to Remove Air Conditioner Condenser Assembly................................................................................................2351 How to Install Air Conditioner Condenser Assembly...............................................................................................2352 Power Train.............................................................................................................................................2355 Disassemble and Assemble PTO Assembly...............................................................................................................2355 How to Disassemble PTO Assembly.................................................................................................................2355 How to Assemble PTO Assembly....................................................................................................................2357 Remove and Install PTO Assembly.....................................................................................................................2361 How to Remove PTO Assembly......................................................................................................................2361 How to Install PTO Assembly.....................................................................................................................2363 Remove and Install Travel Motor and Final Drive Assembly............................................................................................2366 How to Remove Travel Motor and Final Drive Assembly.............................................................................................2366 How to Install Travel Motor and Final Drive Assembly............................................................................................2367 Disassemble and Assemble Final Drive Assembly.......................................................................................................2368 How to Disassemble Final Drive Assembly.........................................................................................................2368 How to Assemble Final Drive Assembly............................................................................................................2373 Remove and Install Swing Motor and Swing Machinery Assembly.........................................................................................2381 How to Remove Swing Motor and Swing Machinery Assembly..........................................................................................2381 How to Install Swing Motor and Swing Machinery Assembly.........................................................................................2383 Disassemble and Assemble Swing Machinery Assembly...................................................................................................2386 How to Disassemble Swing Machinery Assembly.....................................................................................................2386 How to Assemble Swing Machinery Assembly........................................................................................................2390 Remove and Install Swing Circle Assembly............................................................................................................2396 How to Remove Swing Circle Assembly.............................................................................................................2396 How to Install Swing Circle Assembly............................................................................................................2397 Undercarriage and Frame.................................................................................................................................2398 Remove and Install Idler Assembly...................................................................................................................2398 How to Remove Idler Assembly....................................................................................................................2398 How to Install Idler Assembly...................................................................................................................2399 Disassemble and Assemble Recoil Spring Assembly.....................................................................................................2400 How to Disassemble Recoil Spring Assembly.......................................................................................................2400 How to Assemble Recoil Spring Assembly..........................................................................................................2401 Remove and Install Track Roller Assembly............................................................................................................2402 How to Remove Track Roller Assembly.............................................................................................................2402 How to Install Track Roller Assembly............................................................................................................2403 Remove and Install Carrier Roller Assembly..........................................................................................................2405 How to Remove Carrier Roller Assembly...........................................................................................................2405 How to Install Carrier Roller Assembly..........................................................................................................2406 Disassemble and Assemble One Track Link Assembly in Field...........................................................................................2407 How to Disassemble One Track Link Assembly in Field.............................................................................................2409 How to Assemble One Track Link Assembly in Field................................................................................................2410 Separate and Connect Track Assembly.................................................................................................................2413 How to Separate Track Assembly..................................................................................................................2414 How to Install Track Assembly...................................................................................................................2415 Disassemble and Assemble Idler Assembly.............................................................................................................2416 How to Disassemble Idler Assembly...............................................................................................................2416 How to Assemble Idler Assembly..................................................................................................................2418 Disassemble and Assemble Idler Adjustment Cylinder Assembly.........................................................................................2421 How to Disassemble Idler Adjustment Cylinder Assembly...........................................................................................2421 How to Assemble Idler Adjustment Cylinder Assembly..............................................................................................2422 Disassemble and Assemble Track Roller Assembly......................................................................................................2423 How to Disassemble Track Roller Assembly........................................................................................................2423 How to Assemble Track Roller Assembly...........................................................................................................2424 Disassemble and Assemble Carrier Roller Assembly....................................................................................................2427 How to Disassemble Carrier Roller Assembly......................................................................................................2427 How to Assemble Carrier Roller Assembly.........................................................................................................2428 Remove and Install Revolving Frame Assembly.........................................................................................................2430 How to Remove Revolving Frame Assembly..........................................................................................................2430 How to Install Revolving Frame Assembly.........................................................................................................2431 Remove and Install Counterweight Assembly...........................................................................................................2433 How to Remove Counterweight Assembly............................................................................................................2433 How to Install Counterweight Assembly...........................................................................................................2435 Hydraulic System........................................................................................................................................2437 Remove and Install Center Swivel Joint Assembly.....................................................................................................2437 How to Remove Center Swivel Joint Assembly......................................................................................................2437 How to Install Center Swivel Joint Assembly.....................................................................................................2438 Disassemble and Assemble Center Swivel Joint Assembly...............................................................................................2440 How to Disassemble Center Swivel Joint Assembly.................................................................................................2441 How to Assemble Center Swivel Joint Assembly....................................................................................................2442 Remove and Install Hydraulic Tank Assembly..........................................................................................................2443 How to Remove Hydraulic Tank Assembly...........................................................................................................2443 How to Install Hydraulic Tank Assembly..........................................................................................................2447 Remove and Install Hydraulic Pump Assembly..........................................................................................................2452 How to Remove Hydraulic Pump Assembly...........................................................................................................2452 How to Install Hydraulic Pump Assembly..........................................................................................................2464 Remove and Install Control Valve Assembly...........................................................................................................2475 How to Remove Control Valve Assembly............................................................................................................2475 Remove and Install Swing Motor Assembly.............................................................................................................2481 How to Remove Swing Motor Assembly..............................................................................................................2481 How to Install Swing Motor Assembly.............................................................................................................2482 Disassemble and Assemble Work Equipment PPC Valve Assembly..........................................................................................2484 How to Disassemble Work Equipment PPC Valve Assembly............................................................................................2484 Disassemble and Assemble Travel PPC Valve Assembly..................................................................................................2485 How to Assemble Travel PPC Valve Assembly.......................................................................................................2485 Disassemble and Assemble Grease Gun Assembly........................................................................................................2487 How to Disassemble Grease Gun Assembly..........................................................................................................2487 How to Assemble Grease Gun Assembly.............................................................................................................2487 Work Equipment..........................................................................................................................................2488 Remove and Install Bucket Cylinder Assembly.........................................................................................................2488 How to Remove Bucket Cylinder Assembly..........................................................................................................2488 How to Install Bucket Cylinder Assembly.........................................................................................................2489 Remove and Install Bucket Cylinder Assembly (Loading Shovel Specification)..........................................................................2491 How to Remove Bucket Cylinder Assembly (Loading Shovel Specification)...........................................................................2491 How to Install Bucket Cylinder Assembly (Loading Shovel Specification)..........................................................................2492 Remove and Install Arm Cylinder Assembly............................................................................................................2494 How to Remove Arm Cylinder Assembly.............................................................................................................2494 How to Install Arm Cylinder Assembly............................................................................................................2496 Remove and Install Arm Cylinder Assembly (Loading Shovel Specification).............................................................................2498 How to Remove Arm Cylinder Assembly (Loading Shovel Specification)..............................................................................2498 How to Install Arm Cylinder Assembly (Loading Shovel Specification).............................................................................2500 Remove and Install Boom Cylinder Assembly...........................................................................................................2502 How to Remove Boom Cylinder Assembly............................................................................................................2502 How to Install Boom Cylinder Assembly...........................................................................................................2503 Remove and Install Boom Cylinder Assembly (Loading Shovel Specification)............................................................................2505 How to Remove Boom Cylinder Assembly (Loading Shovel Specification).............................................................................2505 How to Install Boom Cylinder Assembly (Loading Shovel Specification)............................................................................2506 Remove and Install Bucket Assembly..................................................................................................................2509 How to Remove Bucket Assembly...................................................................................................................2510 How to Install Bucket Assembly..................................................................................................................2511 Remove and Install Bucket Assembly (Loading Shovel Specification)...................................................................................2513 How to Remove Bucket Assembly (Loading Shovel Specification)....................................................................................2513 How to Install Bucket Assembly (Loading Shovel Specification)...................................................................................2514 Remove and Install Arm Assembly.....................................................................................................................2516 How to Remove Arm Assembly......................................................................................................................2516 How to Install Arm Assembly.....................................................................................................................2517 Remove and Install Arm Assembly (Loading Shovel Specification)......................................................................................2519 How to Remove Arm Assembly (Loading Shovel Specification).......................................................................................2519 How to Install Arm Assembly (Loading Shovel Specification)......................................................................................2520 Remove and Install Boom Assembly....................................................................................................................2522 How to Remove Boom Assembly.....................................................................................................................2522 How to Install Boom Assembly....................................................................................................................2524 Remove and Install Boom Assembly (Loading Shovel Specification).....................................................................................2526 How to Remove Boom Assembly (Loading Shovel Specification)......................................................................................2526 How to Install Boom Assembly (Loading Shovel Specification).....................................................................................2528 Disassemble and Assemble Work Equipment Cylinder Assembly...........................................................................................2530 How to Disassemble Work Equipment Cylinder Assembly.............................................................................................2531 How to Assemble Work Equipment Cylinder Assembly................................................................................................2533 Disassemble and Assemble Bottom Dump Cylinder Assembly (Loading Shovel Specification)...............................................................2538 How to Disassemble Bottom Dump Cylinder Assembly (Loading Shovel Specification).................................................................2538 How to Assemble Bottom Dump Cylinder Assembly (Loading Shovel Specification)....................................................................2544 CAB Related Parts.......................................................................................................................................2549 Remove and Install Top Guard Assembly...............................................................................................................2549 How to Remove Top Guard Assembly................................................................................................................2549 How to Install Top Guard Assembly...............................................................................................................2551 Remove and Install Operator Cab Assembly............................................................................................................2553 How to Remove Operator Cab Assembly.............................................................................................................2553 How to Install Operator Cab Assembly............................................................................................................2562 Remove and Install Operator Cab Glass (Adhered Glass)...............................................................................................2572 How to Remove Operator Cab Glass (Adhered Glass)................................................................................................2574 How to Install Operator Cab Glass (Adhered Glass)...............................................................................................2574 Remove and Install Front Window Assembly............................................................................................................2584 How to Remove Front Window Assembly.............................................................................................................2584 How to Install Front Window Assembly............................................................................................................2587 Remove and Install Floor Frame Assembly.............................................................................................................2593 How to Remove Floor Frame Assembly..............................................................................................................2593 How to Install Floor Frame Assembly.............................................................................................................2599 Remove and Install Air Conditioner Unit Assembly....................................................................................................2606 How to Remove Air Conditioner Unit Assembly.....................................................................................................2606 How to Install Air Conditioner Unit Assembly....................................................................................................2611 Remove and Install Operator Seat....................................................................................................................2618 How to Remove Operator Seat.....................................................................................................................2618 How to Install Operator Seat....................................................................................................................2620 How to Remove and Install Seat Belt.................................................................................................................2623 How to Remove Seat Belt.........................................................................................................................2623 How to Install Seatbelt.........................................................................................................................2623 Remove and Install Front Wiper Assembly.............................................................................................................2625 How to Remove Front Wiper Assembly..............................................................................................................2625 How to Install Front Wiper Assembly.............................................................................................................2630 Electrical System.......................................................................................................................................2639 Remove and Install Engine Controller Assembly.......................................................................................................2639 How to Remove Engine Controller Assembly........................................................................................................2639 How to Install Engine Controller Assembly.......................................................................................................2641 Remove and Install Pump Controller Assembly.........................................................................................................2644 How to Remove Pump Controller Assembly..........................................................................................................2644 How to Install Pump Controller Assembly.........................................................................................................2646 Remove and Install KomVision Controller Assembly....................................................................................................2649 How to Remove KomVision Controller Assembly.....................................................................................................2649 How to Install KomVision Controller Assembly....................................................................................................2650 Remove and Install Machine Monitor Assembly.........................................................................................................2651 How to Remove Machine Monitor Assembly..........................................................................................................2651 How to Install Machine Monitor Assembly.........................................................................................................2653 Remove and Install Mass Air Flow and Temperature Sensor.............................................................................................2657 How to Remove Mass Air Flow and Temperature Sensor..............................................................................................2657 How to Install Mass Air Flow and Temperature Sensor.............................................................................................2658 Remove and Install KCCV Crankcase Pressure Sensor...................................................................................................2660 How to Remove KCCV Crankcase Pressure Sensor....................................................................................................2660 How to Install KCCV Crankcase Pressure Sensor...................................................................................................2661 Remove and Install KomVision Camera.................................................................................................................2663 How to Remove KomVision Camera..................................................................................................................2663 How to Install KomVision Camera.................................................................................................................2664 Remove and Install KOMTRAX Terminal Assembly........................................................................................................2666 How to Remove KOMTRAX Terminal Assembly.........................................................................................................2666 How to Install KOMTRAX Terminal Assembly........................................................................................................2668 Remove And Install KOMTRAX Plus Controller Assembly.................................................................................................2670 How to Remove KOMTRAX Plus Controller Assembly..................................................................................................2670 How to Install KOMTRAX Plus Controller Assembly.................................................................................................2671 Remove and Install Wireless LAN Unit Assembly.......................................................................................................2672 How to Remove Wireless LAN Unit Assembly........................................................................................................2672 How to Install Wireless LAN Unit Assembly.......................................................................................................2673 60 Maintenance Standard.....................................................................................................................................2677 Table of Contents.......................................................................................................................................2678 Engine and Cooling System...............................................................................................................................2679 Maintenance Standard for Engine Mount...............................................................................................................2679 Maintenance Standard for PTO........................................................................................................................2681 Maintenance Standard for Cooling System.............................................................................................................2682 Maintenance Standard for Cooling Fan Pump...........................................................................................................2684 Maintenance Standard for EPC Valve of Cooling Fan Pump..........................................................................................2686 Maintenance Standard for Cooling Fan Motor..........................................................................................................2687 Power Train.............................................................................................................................................2689 Maintenance Standard for Swing Circle...............................................................................................................2689 Maintenance Standard for Swing Machinery............................................................................................................2690 Maintenance Standard for Final Drive................................................................................................................2692 Maintenance Standard for Sprocket...................................................................................................................2694 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing..................................................................................2695 Undercarriage and Frame.................................................................................................................................2696 Maintenance Standard for Track Frame and Idler Cushion..............................................................................................2696 Maintenance Standard for Idler......................................................................................................................2698 Maintenance Standard for Track Roller...............................................................................................................2700 Maintenance Standard for Track Shoes................................................................................................................2701 Hydraulic System........................................................................................................................................2704 Maintenance Standard for Main Pump..................................................................................................................2704 Maintenance Standard for Swing Motor................................................................................................................2708 Maintenance Standard for Control Valve..............................................................................................................2711 Maintenance Standard for Straight Travel Valve of Control Valve.................................................................................2722 Maintenance Standard for Variable Back Pressure Valve...............................................................................................2723 Maintenance Standard for Work Equipment and Swing PPC Valve.........................................................................................2724 Maintenance Standard for Travel PPC Valve...........................................................................................................2727 Maintenance Standard for Solenoid Valve.............................................................................................................2729 Maintenance Standard for Center Swivel Joint........................................................................................................2730 Work Equipment..........................................................................................................................................2731 Maintenance Standard for Work Equipment Linkage.....................................................................................................2731 Dimensions of Arm...............................................................................................................................2734 Dimensions of Bucket............................................................................................................................2736 Maintenance Standard for Work Equipment Linkage (Loading Shovel Specification)......................................................................2738 Dimensions of Arm (Loading Shovel Specification)................................................................................................2741 Dimensions of Bucket (Loading Shovel Specification).............................................................................................2743 Maintenance Standard for Boom Cylinder..............................................................................................................2745 Maintenance Standard for Boom Cylinder (Loading Shovel Specification)...............................................................................2746 Maintenance Standard for Arm Cylinder...............................................................................................................2747 Maintenance Standard for Arm Cylinder (Loading Shovel Specification)................................................................................2748 Maintenance Standard for Bucket Cylinder............................................................................................................2749 Dimensions of Bucket (Loading Shovel Specification).................................................................................................2750 80 Appendix.................................................................................................................................................2753 Table of Contents.......................................................................................................................................2754 Precautions Before Work.................................................................................................................................2756 Air Conditioner System..................................................................................................................................2757 Precautions for Refrigerant.........................................................................................................................2757 Air Conditioner Component...........................................................................................................................2758 Specifications of Air Conditioner...................................................................................................................2760 Structure and Function of Refrigeration Cycle.......................................................................................................2761 Outline of Refrigeration Cycle......................................................................................................................2762 Component Parts of Air Conditioner System...............................................................................................................2764 Air Conditioner Unit................................................................................................................................2764 Configuration Diagram of Air Conditioner Unit...................................................................................................2764 Function of Air Conditioner Unit................................................................................................................2766 Component Parts of Air Conditioner Unit.............................................................................................................2768 Function of Evaporator as Air Conditioner Unit Component........................................................................................2769 Function of Heater Core as Air Conditioner Unit Component.......................................................................................2769 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.....................................................................2769 Function of Servo Motor as Air Conditioner Unit Component.......................................................................................2769 Structure of Expansion Valve as Air Conditioner Unit Component..................................................................................2770 Function of Expansion Valve as Air Conditioner Unit Component...................................................................................2770 Operate Expansion Valve as Air Conditioner Unit Component.......................................................................................2770 Function of Dual Pressure Switch................................................................................................................2771 Air Conditioner Controller..........................................................................................................................2772 Structure of Air Conditioner Controller.........................................................................................................2772 Compressor..........................................................................................................................................2773 Structure of Compressor.........................................................................................................................2773 Specifications of Compressor....................................................................................................................2773 Function of Compressor..........................................................................................................................2773 Condenser...........................................................................................................................................2774 Structure of Condenser..........................................................................................................................2774 Specifications of Condenser.....................................................................................................................2774 Function of Condenser...........................................................................................................................2774 Receiver Drier......................................................................................................................................2775 Structure of Receiver Dryer.....................................................................................................................2775 Specifications of Receiver Dryer................................................................................................................2775 Function of Receiver Dryer......................................................................................................................2775 Air Conditioner Related Sensors.....................................................................................................................2776 Structure of Sunlight Sensor....................................................................................................................2776 Function of Sunlight Sensor.....................................................................................................................2776 Structure of Outside Temperature Sensor.........................................................................................................2776 Function of Outside Air Temperature Sensor......................................................................................................2776 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.............................................................................2778 Circuit Diagram and Configuration of Connector Pins of Air Conditioner..................................................................................2780 System Diagram of Air Conditioner.......................................................................................................................2782 Input and Output Signals of Air Conditioner Controller..............................................................................................2783 Function of Air Conditioner Controller..........................................................................................................2784 Locations of Air Conditioner Parts and Layout of Connectors.............................................................................................2785 Examine Air Leakage (Duct)..............................................................................................................................2789 How to Examine Air Leakage (Duct)...................................................................................................................2789 Examine Air Conditioner with Self-Diagnosis Function....................................................................................................2791 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.................................................................2792 Examine Vent (Mode) Changeover..........................................................................................................................2793 How to Examine Vent (Mode) Changeover...............................................................................................................2793 Examine Fresh/Recirc Air Changeover.....................................................................................................................2795 How to Examine Fresh/Recirc Air Changeover..........................................................................................................2795 Examine Sunlight Sensor.................................................................................................................................2796 How to Examine Sunlight Sensor......................................................................................................................2796 Examine Refrigerant (Dual) Pressure Switch..............................................................................................................2797 How to Examine Refrigerant (Dual) Pressure Switch...................................................................................................2797 Examine Relay...........................................................................................................................................2798 How to Examine Relay................................................................................................................................2798 Air Conditioner Troubleshooting Chart 1.................................................................................................................2799 Air Conditioner Troubleshooting Chart 2.................................................................................................................2800 Information Shown in Troubleshooting Table..............................................................................................................2803 Failure Code [879AKA]...................................................................................................................................2804 Failure Code [879AKB]...................................................................................................................................2805 Failure Code [879BKA]...................................................................................................................................2806 Failure Code [879BKB]...................................................................................................................................2808 Failure Code [879CKA]...................................................................................................................................2810 Failure Code [879CKB]...................................................................................................................................2811 Failure Code [879DKZ]...................................................................................................................................2812 Failure Code [879EMC]...................................................................................................................................2814 Failure Code [879FMC]...................................................................................................................................2815 Failure Code [879GKX]...................................................................................................................................2816 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)..........................................................................2818 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)...........................................................................2820 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..................................................................2823 A-4 Troubleshooting for Fresh/Recirc Air Changeover.....................................................................................................2825 Troubleshooting by Gauge Pressure.......................................................................................................................2827 Connect Service Tool....................................................................................................................................2830 How to Connect Service Tool.........................................................................................................................2830 Precautions for Disconnection and Connection of Air Conditioner Piping..................................................................................2832 Handle Compressor Oil...................................................................................................................................2834 90 Circuit Diagrams.........................................................................................................................................2837 Table of Contents.......................................................................................................................................2838 Hydraulic Circuit Diagram...............................................................................................................................2839 Symbols Used in Hydraulic Circuit Diagram...........................................................................................................2839 Hydraulic Circuit Diagram...........................................................................................................................2843 Electrical Circuit Diagram..............................................................................................................................2845 Symbols Used in Electric Circuit Diagram............................................................................................................2845 Electrical Circuit Diagram (1/14)...................................................................................................................2849 Electrical Circuit Diagram (2/14)...................................................................................................................2851 Electrical Circuit Diagram (3/14)...................................................................................................................2853 Electrical Circuit Diagram (4/14)...................................................................................................................2855 Electrical Circuit Diagram (5/14)...................................................................................................................2857 Electrical Circuit Diagram (6/14)...................................................................................................................2859 Electrical Circuit Diagram (7/14)...................................................................................................................2861 Electrical Circuit Diagram (8/14)...................................................................................................................2863 Electrical Circuit Diagram (9/14)...................................................................................................................2865 Electrical Circuit Diagram (10/14)..................................................................................................................2867 Electrical Circuit Diagram (11/14)..................................................................................................................2869 Electrical Circuit Diagram (12/14)..................................................................................................................2871 Electrical Circuit Diagram (13/14)..................................................................................................................2873 Electrical Circuit Diagram (14/14)..................................................................................................................2875 Electrical Circuit Diagram (1/14) (Loading Shovel Specification)....................................................................................2877 Electrical Circuit Diagram (2/14) (Loading Shovel Specification)....................................................................................2879 Electrical Circuit Diagram (3/14) (Loading Shovel Specification)....................................................................................2881 Electrical Circuit Diagram (4/14) (Loading Shovel Specification)....................................................................................2883 Electrical Circuit Diagram (5/14) (Loading Shovel Specification)....................................................................................2885 Electrical Circuit Diagram (6/14) (Loading Shovel Specification)....................................................................................2887 Electrical Circuit Diagram (7/14) (Loading Shovel Specification)....................................................................................2889 Electrical Circuit Diagram (8/14) (Loading Shovel Specification)....................................................................................2891 Electrical Circuit Diagram (9/14) (Loading Shovel Specification)....................................................................................2893 Electrical Circuit Diagram (10/14) (Loading Shovel Specification)...................................................................................2895 Electrical Circuit Diagram (11/14) (Loading Shovel Specification)...................................................................................2897 Electrical Circuit Diagram (12/14) (Loading Shovel Specification)...................................................................................2899 Electrical Circuit Diagram (13/14) (Loading Shovel Specification)...................................................................................2901 Electrical Circuit Diagram (14/14) (Loading Shovel Specification)...................................................................................2903 Index........................................................................................................................................................2905
DESCRIPTION:
KOMATSU PC1250-11 PC1250SP-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06657-10 – 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 29/12/24
