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KOMATSU PC2000-11 E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06889-06 – PDF DOWNLOAD
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KOMATSU PC2000-11 E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06889-06 – PDF DOWNLOAD
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KOMATSU PC2000-11 E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06889-06 – PDF DOWNLOAD
Language : English
Pages : 4146
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC2000-11 E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06889-06 – PDF DOWNLOAD
Cover...................................................................................................................................................... 2 00 Index and Foreword................................................................................................................................. 3 Index............................................................................................................................................. 4 Abbreviation List................................................................................................................................. 25 Foreword, Safety, Basic Information............................................................................................................... 28 How to Read the Shop Manual................................................................................................................... 28 Safety Notice for Operation................................................................................................................... 30 Precautions to Prevent Fire................................................................................................................... 38 Procedures If Fire Occurs..................................................................................................................... 40 Precautions When You Discard Waste Materials.................................................................................................. 41 Precautions When You Handle Hydraulic Equipment............................................................................................... 42 Precautions When You Disconnect and Connect Pipings........................................................................................... 45 Precautions When You Handle Electrical Equipment.............................................................................................. 51 Precautions When You Handle Fuel System Equipment............................................................................................. 53 Precautions When You Handle Intake System Equipment........................................................................................... 54 Practical Use of KOMTRAX...................................................................................................................... 55 Disconnect and Connect Push-Pull Type Coupler................................................................................................. 56 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................... 56 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................... 57 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................... 58 Precautions for Disconnection and Connection of Connectors.................................................................................... 60 How to Disconnect and Connect Deutsch Connector............................................................................................... 64 How to Disconnect and Connect Slide Lock Type Connector....................................................................................... 65 How to Disconnect and Connect Connector with Lock to Pull..................................................................................... 67 How to Disconnect and Connect Connector with Lock to Push..................................................................................... 68 How to Disconnect and Connect Connector with Housing to Rotate................................................................................ 70 How to Disconnect and Connect Molex Connector................................................................................................. 71 How to Read the Codes for Electric Cable...................................................................................................... 72 Explanation of Terms for Maintenance Standard................................................................................................. 76 Standard Tightening Torque Table.............................................................................................................. 79 Conversion Table.............................................................................................................................. 86 01 Specifications..................................................................................................................................... 91 Table of Contents................................................................................................................................. 92 Specifications.................................................................................................................................... 93 Specification Drawing......................................................................................................................... 93 Specification Drawing: PC2000-11E0........................................................................................................ 93 Specification Drawing: PC2000-11E0 (Loading Shovel Specification)......................................................................... 94 Working Range Drawings........................................................................................................................ 96 Working Range Drawings: PC2000-11E0....................................................................................................... 96 Working Range Drawings: PC2000-11E0 (Loading Shovel Specification)........................................................................ 97 Specifications................................................................................................................................ 98 Specification: PC2000-11E0................................................................................................................ 98 Specifications: PC2000-11E0 (Loading Shovel Specification)................................................................................ 101 Weight Table.................................................................................................................................. 105 Weight Table: PC2000-11E0................................................................................................................. 105 Weight Table: PC2000-11E0 (Loading Shovel Specification).................................................................................. 108 Fuel, Coolant, Lubricants (For European Union)................................................................................................ 112 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 112 10 Structure and Function............................................................................................................................. 115 Table of Contents................................................................................................................................. 116 NOx Control System................................................................................................................................ 120 Function of NOx Control System................................................................................................................ 120 Inducement Strategy....................................................................................................................... 120 Inducement Strategy When Abnormality is Found in the EGR System (EU Specification)........................................................ 120 Function of Temporary Restoration from Inducement (EU Specification)...................................................................... 121 Inducement Strategy for Abnormality Recurrence (EU Specification)......................................................................... 122 Boot-up System.................................................................................................................................... 123 Layout Drawing of Boot-up System.............................................................................................................. 123 System Operating Lamp System.................................................................................................................. 124 System Diagram of System Operating Lamp System............................................................................................ 124 Function of Operation Lamp System......................................................................................................... 124 Battery Isolator.............................................................................................................................. 126 Layout Drawing of Battery Isolator........................................................................................................ 126 Function of Battery Isolator.............................................................................................................. 126 Function of Starting Motor Isolator Switch................................................................................................ 127 Engine System..................................................................................................................................... 128 Layout Drawing of Engine System............................................................................................................... 128 Function of Engine System................................................................................................................. 129 Engine Control System......................................................................................................................... 130 System Diagram of Engine Control.......................................................................................................... 130 Operation of Engine Control System........................................................................................................ 131 Auto-Deceleration System...................................................................................................................... 132 System Diagram of Auto-Deceleration System................................................................................................ 132 Function of Auto-Deceleration System...................................................................................................... 133 Operation of Auto-Deceleration System..................................................................................................... 133 Automatic Low Idle System..................................................................................................................... 134 Automatic Low Idle System Diagram......................................................................................................... 134 Function of Automatic Low Idle System..................................................................................................... 134 Operation of Automatic Low Idle System.................................................................................................... 135 Engine Automatic Warm-up System............................................................................................................... 136 System Diagram of Engine Automatic Warm-up System......................................................................................... 136 Function of Engine Automatic Warm-up System............................................................................................... 136 Overheat Prevention System.................................................................................................................... 138 Overheat Prevention System Diagram........................................................................................................ 138 Function of Overheat Prevention System.................................................................................................... 138 Turbocharger Protection System................................................................................................................ 140 System Diagram of Turbocharger Protection System.......................................................................................... 140 Function of Turbocharger Protection System................................................................................................ 140 Multiple Injection Control System............................................................................................................. 142 Function of Multiple Injection Control System............................................................................................. 142 Component Parts of Engine System.............................................................................................................. 143 PTO....................................................................................................................................... 143 VGT....................................................................................................................................... 145 EGR System................................................................................................................................ 148 EGR Valve................................................................................................................................. 152 EGR Cooler................................................................................................................................ 153 KCCV System............................................................................................................................... 154 KCCV Ventilator........................................................................................................................... 157 KDPF...................................................................................................................................... 159 Cooling System.................................................................................................................................... 164 Layout Drawing of Cooling System.............................................................................................................. 164 Specifications of Cooling System.......................................................................................................... 165 Fan Speed Control System of Hydraulic Fan..................................................................................................... 166 Fan Speed Control System Diagram of Hydraulic Fan......................................................................................... 166 Function of Fan Speed Control System of Hydraulic Fan..................................................................................... 167 Engine Output Control System of Hydraulic Fan................................................................................................. 168 Engine Output Control System Diagram of Hydraulic Fan..................................................................................... 168 Function of Engine Output Control System of Hydraulic Fan................................................................................. 168 Fan Reverse Rotation System of Hydraulic Fan.................................................................................................. 169 Fan Reverse Rotation System Diagram of Hydraulic Fan...................................................................................... 169 Function of Fan Reverse Rotation System of Hydraulic Fan.................................................................................. 169 Component Parts of Cooling System............................................................................................................. 170 Cooling Fan Pump.......................................................................................................................... 170 Cooling Fan Motor......................................................................................................................... 184 Control System.................................................................................................................................... 191 Layout Drawing of Control System.............................................................................................................. 191 Machine Monitor System........................................................................................................................ 193 System Diagram of Machine Monitor System.................................................................................................. 193 KOMTRAX Plus System........................................................................................................................... 195 System Diagram of KOMTRAX Plus System..................................................................................................... 195 Function of KOMTRAX Plus System........................................................................................................... 195 Component Parts of Control System............................................................................................................. 200 Machine Monitor........................................................................................................................... 200 KOMTRAX Terminal.......................................................................................................................... 214 KOMTRAX Plus Controller................................................................................................................... 216 Wireless LAN Unit......................................................................................................................... 220 Pump Controller........................................................................................................................... 222 Valve Controller 1........................................................................................................................ 226 Valve Controller 2........................................................................................................................ 230 Resistor for Pump Secondary Drive......................................................................................................... 234 CAN Terminating Resistor.................................................................................................................. 234 Engine Controller......................................................................................................................... 235 Fuel Control Dial......................................................................................................................... 248 Fuel Feed Pump............................................................................................................................ 249 Fuel Feed Pump Switch..................................................................................................................... 250 Hydraulic System.................................................................................................................................. 251 Layout Drawing of Hydraulic System............................................................................................................ 251 Electronic OLSS............................................................................................................................... 254 Structure of Electronic OLSS.............................................................................................................. 254 Function of Electronic OLSS............................................................................................................... 255 Engine and Pump Combined Control System....................................................................................................... 257 Engine and Pump Combined Control System Diagram........................................................................................... 257 Function of Engine and Pump Combined Control System....................................................................................... 258 Component Parts of Hydraulic System........................................................................................................... 261 Hydraulic Tank............................................................................................................................ 261 Main Pump................................................................................................................................. 262 Control Valve............................................................................................................................. 282 Variable Back Pressure Valve.............................................................................................................. 314 Work Equipment System............................................................................................................................. 317 Layout Drawing of Work Equipment System....................................................................................................... 317 Layout Drawing of Work Equipment System (Loading Shovel Specification)........................................................................ 323 Work Equipment System Diagram................................................................................................................. 329 Machine Push-up System........................................................................................................................ 330 Machine Push-up System Diagram............................................................................................................ 330 Function of Machine Push-up System........................................................................................................ 330 Heavy Lift System............................................................................................................................. 332 Heavy Lift System Diagram................................................................................................................. 332 Function of Heavy Lift System............................................................................................................. 332 Operation of Heavy Lift System............................................................................................................ 333 Boom Shockless Control Function............................................................................................................... 334 Boom Shockless Control Function System Diagram............................................................................................ 334 Operation of Boom Shockless Control Function.............................................................................................. 334 PPC Lock System............................................................................................................................... 335 System Diagram of PPC Lock................................................................................................................ 335 Function of PPC Lock System............................................................................................................... 335 Work Equipment and Travel Automatic Lock System............................................................................................... 336 System Diagram of Lock Lever Automatic Lock System........................................................................................ 336 Function of Work Equipment and Travel Automatic Lock System............................................................................... 336 Operation of Lock Lever Automatic Lock System............................................................................................. 336 Component Parts of Work Equipment System...................................................................................................... 338 Work Equipment and Swing PPC Valve........................................................................................................ 338 Suction Selector Valve.................................................................................................................... 343 PPC Cut-off Valve......................................................................................................................... 346 Solenoid Valve............................................................................................................................ 351 Pilot Circuit Accumulator................................................................................................................. 356 Swing System...................................................................................................................................... 357 Layout Drawing of Swing System................................................................................................................ 357 Swing Control System Diagram.................................................................................................................. 360 Function of Swing Control System.......................................................................................................... 360 Swing Priority System Diagram................................................................................................................. 363 Operation of Swing Priority System........................................................................................................ 364 Component Parts of Swing System............................................................................................................... 365 Swing Motor............................................................................................................................... 365 Swing Machinery........................................................................................................................... 374 Swing Circle.............................................................................................................................. 375 Travel System..................................................................................................................................... 377 Layout Drawing of Travel System............................................................................................................... 377 System Diagram of Travel Control System....................................................................................................... 381 Travel Straight System Diagram................................................................................................................ 382 Operation of Travel Straight System....................................................................................................... 383 HIC System.................................................................................................................................... 385 Layout Drawing of HIC System.............................................................................................................. 385 HIC System Diagram........................................................................................................................ 386 Operation of HIC System................................................................................................................... 386 Component Parts of Travel System.............................................................................................................. 389 Travel Motor.............................................................................................................................. 389 Final Drive............................................................................................................................... 402 Travel PPC Valve.......................................................................................................................... 403 Center Swivel Joint....................................................................................................................... 407 Accumulator for HIC System.................................................................................................................... 408 Structure of Accumulator for HIC System................................................................................................... 408 Specifications of Accumulator for HIC System.............................................................................................. 408 Lifting System.................................................................................................................................... 409 Hydraulically Operated Stairway System........................................................................................................ 409 Layout Drawing of Hydraulically Operated Stairway System.................................................................................. 409 Hydraulically Operated Stairway System Diagram............................................................................................ 410 Function of Hydraulically Operated Stairway System........................................................................................ 410 Component Parts of Lifting System............................................................................................................. 411 Switch Box................................................................................................................................ 411 Proximity Switch Part..................................................................................................................... 411 Control Valve Assembly.................................................................................................................... 412 Service Center System............................................................................................................................. 413 Layout Drawing of Service Center System....................................................................................................... 413 Service Center System Diagram................................................................................................................. 415 Function of Service Center System......................................................................................................... 415 Component Parts of Service Center System...................................................................................................... 417 Raise/Lower Switch........................................................................................................................ 417 Proximity Switch Part..................................................................................................................... 417 Control Valve Assembly.................................................................................................................... 418 Left Console Box Section in CAB........................................................................................................... 419 Service Panel Part........................................................................................................................ 419 Grease Lubrication System......................................................................................................................... 422 Grease Lubrication System Diagram............................................................................................................. 422 Function of Grease Lubrication System..................................................................................................... 424 Specifications of Grease Lubrication System............................................................................................... 425 Component Parts of Grease Lubrication System.................................................................................................. 426 Grease Pump............................................................................................................................... 426 Grease Gun................................................................................................................................ 428 Hose Reel................................................................................................................................. 428 Injector Distribution Valve............................................................................................................... 429 Undercarriage and Frame........................................................................................................................... 432 Layout Drawing of Undercarriage............................................................................................................... 432 Specifications of Undercarriage........................................................................................................... 432 Work Equipment.................................................................................................................................... 433 Structure of Work Equipment................................................................................................................... 433 Structure of Work Equipment (Loading Shovel Specification).................................................................................... 434 Function of Work Equipment.................................................................................................................... 435 Work Equipment Clearance Adjustment Shim...................................................................................................... 436 Function of Work Equipment Clearance Adjustment Shim...................................................................................... 436 CAB Related Parts................................................................................................................................. 437 CAB........................................................................................................................................... 437 Structure of CAB.......................................................................................................................... 437 Wiper System.................................................................................................................................. 438 Layout Drawing of Wiper System............................................................................................................ 438 Wiper System Diagram...................................................................................................................... 439 Function of Wiper System.................................................................................................................. 439 CAB Mount..................................................................................................................................... 442 Structure of CAB Mount.................................................................................................................... 442 Function of CAB Mount..................................................................................................................... 442 20 Standard Value Table............................................................................................................................... 443 Table of Contents................................................................................................................................. 444 Standard Value Table for Engine................................................................................................................... 445 Standard Value Table for Engine: PC2000-11E0.................................................................................................. 445 Standard Value Table for Machine.................................................................................................................. 450 Standard Value Table for Machine: PC2000-11E0 (Backhoe Specification)......................................................................... 450 Standard Value Table for Machine: PC2000-11E0 (Loading Shovel Specification).................................................................. 467 Machine Posture and Procedures to Measure Performance (Backhoe Specification)................................................................. 486 Machine Posture and Procedures to Measure Performance (Loading Shovel Specification).......................................................... 489 30 Testing and Adjusting.............................................................................................................................. 493 Table of Contents................................................................................................................................. 494 Precautions Before Work........................................................................................................................... 498 Related Information on Testing and Adjusting...................................................................................................... 499 Tools for Testing and Adjusting............................................................................................................... 499 Engine and Cooling System......................................................................................................................... 507 Examine Engine Speed.......................................................................................................................... 507 How to Examine Engine Speed............................................................................................................... 507 Examine Boost Pressure........................................................................................................................ 510 How to Examine Boost Pressure on Machine Monitor.......................................................................................... 510 How to Examine Boost Pressure by Testing Tool............................................................................................. 511 Examine Exhaust Gas Temperature............................................................................................................... 514 How to Examine Exhaust Gas Temperature.................................................................................................... 514 Examine Exhaust Gas Color..................................................................................................................... 515 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................. 515 How to Examine Exhaust Gas Color with Smoke Meter......................................................................................... 518 Examine and Adjust Valve Clearance............................................................................................................ 521 How to Examine Valve Clearance............................................................................................................ 521 How to Adjust Valve Clearance............................................................................................................. 522 Examine Compression Pressure.................................................................................................................. 524 How to Examine Compression Pressure....................................................................................................... 524 Examine Blowby Pressure....................................................................................................................... 528 How to Examine Blowby Pressure by Testing Tool............................................................................................ 528 Examine Engine Oil Pressure................................................................................................................... 534 How to Examine Engine Oil Pressure on Machine Monitor..................................................................................... 534 How to Examine Engine Oil Pressure by Testing Tool........................................................................................ 534 Examine EGR Valve and VGT Oil Pressure........................................................................................................ 536 How to Examine EGR Valve and VGT Oil Pressure............................................................................................. 536 Examine Fuel Pressure......................................................................................................................... 538 How to Examine Fuel Pressure.............................................................................................................. 538 Examine Fuel Return Rate and Leakage.......................................................................................................... 540 How to Examine Fuel Return Rate and Leakage............................................................................................... 541 Bleed Air from Fuel System.................................................................................................................... 546 How to Bleed Air from Fuel System......................................................................................................... 547 Examine Fuel Circuit for Leakage.............................................................................................................. 549 How to Examine Fuel System for Leakage.................................................................................................... 549 Examine Supply Pump........................................................................................................................... 551 How to Examine Supply Pump................................................................................................................ 551 Handle Cylinder Cut-out Mode Operation........................................................................................................ 555 Examine Alternator............................................................................................................................ 556 How to Examine Alternator................................................................................................................. 556 Examine and Adjust Alternator Belt Tension.................................................................................................... 557 How to Examine Alternator Belt Tension.................................................................................................... 557 How to Adjust Tension of Alternator Belt.................................................................................................. 558 Handle No-Injection Cranking Operation........................................................................................................ 559 Examine and Adjust Air Conditioner Compressor Belt Tension.................................................................................... 560 How to Examine Air Conditioner Compressor Belt Tension.................................................................................... 560 How to Adjust Air Conditioner Compressor Belt Tension..................................................................................... 561 Clean Fuel Doser.............................................................................................................................. 562 How to Clean Fuel Doser................................................................................................................... 562 Write Injector Compensation Value to Engine Controller........................................................................................ 565 How to Write Injector Compensation Value.................................................................................................. 565 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................................ 571 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................. 571 Power Train....................................................................................................................................... 572 Examine Swing Circle Bearing Clearance........................................................................................................ 572 How to Examine Swing Circle Bearing Clearance............................................................................................. 572 Release Remained Pressure from HIC Circuit.................................................................................................... 573 How to Release Remained Pressure from HIC Circuit......................................................................................... 573 Examine and Charge HIC Circuit Accumulator Nitrogen Gas Pressure.............................................................................. 574 How to Examine HIC Circuit Accumulator Nitrogen Gas....................................................................................... 574 How to Charge HIC Circuit Accumulator Nitrogen Gas........................................................................................ 577 Bleed Air from HIC Circuit.................................................................................................................... 580 How to Bleed Air from HIC Circuit......................................................................................................... 580 Undercarriage and Frame........................................................................................................................... 582 Examine Sprocket Wear......................................................................................................................... 582 How to Examine Sprocket Wear.............................................................................................................. 582 Examine and Adjust Track Tension.............................................................................................................. 583 How to Examine Track Tension.............................................................................................................. 583 How to Adjust Track Tension............................................................................................................... 583 Hydraulic System.................................................................................................................................. 586 Release Remained Pressure in Hydraulic Circuit................................................................................................ 586 How to Release Remained Pressure in Hydraulic System...................................................................................... 586 How to Release Remained Pressure from Hydraulic Tank...................................................................................... 586 How to Release Remained Pressure in Hydraulic Cylinder Circuit............................................................................ 586 How to Release Remained Pressure from Swing Motor Circuit................................................................................. 586 How to Release Remained Pressure from Travel Motor Circuit................................................................................ 587 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits................................................................. 588 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits................................................................. 591 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits.................................................................. 598 Examine and Adjust Oil Pressure in Control Circuit............................................................................................ 602 How to Examine Oil Pressure in Control Circuit............................................................................................ 602 How to Adjust Oil Pressure in Control Circuit............................................................................................. 603 Examine Pump EPC Solenoid Valve Outlet Pressure............................................................................................... 604 How to Examine Pump EPC Solenoid Valve Outlet Pressure.................................................................................... 604 How to Examine Pump EPC Solenoid Valve Electric Current................................................................................... 605 Examine and Adjust Jet Sensor Differential Pressure........................................................................................... 606 How to Examine Jet Sensor Differential Pressure with Machine Monitor...................................................................... 606 How to Examine Jet Sensor Differential Pressure by Testing Tool........................................................................... 607 How to Examine Jet Sensor Differential Pressure........................................................................................... 608 How to Adjust Jet Sensor Differential Pressure............................................................................................ 608 Examine Outlet Pressure of Solenoid Valve..................................................................................................... 610 How to Examine Outlet Pressure of Solenoid Valve.......................................................................................... 610 Operating Condition of Solenoid Valve..................................................................................................... 612 Examine Outlet Pressure of EPC Solenoid Valve................................................................................................. 614 How to Examine Outlet Pressure of EPC Solenoid Valve...................................................................................... 614 Examine PPC Valve Outlet Pressure............................................................................................................. 616 How to Examine Outlet Pressure in PPC Valve............................................................................................... 617 Adjust Play of Work Equipment and Swing PPC Valves............................................................................................ 619 How to Adjust Play of Work Equipment and Swing PPC Valves................................................................................. 619 Examine Travel Deviation...................................................................................................................... 620 How to Examine Travel Deviation........................................................................................................... 620 How to Adjust Travel Deviation............................................................................................................ 620 Examine Fan Speed............................................................................................................................. 621 How to Examine Radiator Fan Speed......................................................................................................... 621 How to Examine Oil Cooler Fan Speed....................................................................................................... 621 Examine Oil Pressure in Fan Pump Circuit...................................................................................................... 622 How to Examine Radiator Fan Pump Circuit Oil Pressure by Machine Monitor.................................................................. 622 How to Examine Radiator Fan Pump Circuit Oil Pressure by Testing Tool..................................................................... 622 How to Examine Oil Cooler Fan Pump Circuit Oil Pressure by Machine Monitor................................................................ 623 How to Examine Oil Cooler Fan Pump Circuit Oil Pressure by Testing Tool................................................................... 623 Examine Fan Pump EPC Electric Current......................................................................................................... 625 How to Examine Radiator Fan Pump EPC Electric Current..................................................................................... 625 How to Examine Oil Cooler Fan Pump EPC Electric Current................................................................................... 625 Examine Fan Pump EPC Solenoid Valve Outlet Pressure........................................................................................... 626 How to Examine Radiator Fan Pump EPC Solenoid Valve Outlet Pressure....................................................................... 626 How to Examine Outlet Pressure of EPC Solenoid Valve of Oil Cooler Fan Pump............................................................... 627 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................................... 628 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder..................................................... 628 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder...................................................................... 628 How to Examine Parts that Cause Hydraulic Drift of PPC Valve.............................................................................. 629 Examine Oil Leakage........................................................................................................................... 630 How to Examine Oil Leakage from Boom Cylinder............................................................................................. 630 How to Examine Oil Leakage from Arm Cylinder.............................................................................................. 631 How to Examine Oil Leakage from Bucket Cylinder........................................................................................... 631 How to Examine Oil Leakage from Swing Motor............................................................................................... 632 How to Examine Oil Leakage from Travel Motor.............................................................................................. 632 How to Examine Oil Leakage of Swivel Joint................................................................................................ 633 Bleed Air from Hydraulic System............................................................................................................... 635 How to Bleed Air from Hydraulic System.................................................................................................... 636 CAB Related Parts................................................................................................................................. 643 How to Adjust Mirrors......................................................................................................................... 643 Procedure to Adjust Machine Left Front Mirror (A)......................................................................................... 643 Procedure to Adjust Regular Position of Machine Left Front Mirror (A)..................................................................... 644 Procedure to Adjust Machine Left Front Mirror (B)......................................................................................... 645 Procedure to Adjust Regular Position of Machine Left Front Mirror (B)..................................................................... 645 Procedure to Adjust Machine Left Rear Mirror (C).......................................................................................... 646 Procedure to Adjust Regular Position of Machine Left Rear Mirror (C)...................................................................... 647 Procedure to Adjust Machine Right Center Mirror (D)....................................................................................... 648 Procedure to Adjust Regular Position of Machine Right Center Mirror (D)................................................................... 648 Automatic Lubrication System...................................................................................................................... 651 Examine and Adjust Automatic Lubrication System............................................................................................... 651 How to Examine Auto-Greasing System....................................................................................................... 651 How to Adjust Automatic Lubrication System................................................................................................ 653 Lifting System.................................................................................................................................... 655 Examine and Adjust Hydraulically Operated Stairway Proximity Switch........................................................................... 655 How to Examine Clearance of Hydraulically Operated Stairway Proximity Switch.............................................................. 655 How to Adjust Clearance of Hydraulically Operated Stairway Proximity Switch............................................................... 656 How to Examine Position of Hydraulically Operated Stairway Position Detecting Plate....................................................... 657 How to Adjust Position of Hydraulically Operated Stairway Position Detecting Plate........................................................ 657 Service Center System............................................................................................................................. 659 Examine and Adjust Service Arm Proximity Switch............................................................................................... 659 How to Examine Clearance of Service Arm Proximity Switch.................................................................................. 659 How to Adjust Clearance of Service Arm Proximity Switch................................................................................... 659 Electrical System................................................................................................................................. 660 Set and Operate Machine Monitor............................................................................................................... 660 Operator Mode............................................................................................................................. 664 Function to Show Technician Identification Status Screen.................................................................................. 664 Function to Show Operator Identification Input Screen..................................................................................... 664 Examine Function by LCD (Liquid Crystal Display).......................................................................................... 665 Examine Function of Service Meter......................................................................................................... 665 Usage Limitation and Maintenance Password Change Function................................................................................. 665 Service Mode.............................................................................................................................. 668 How to Operate Service Mode............................................................................................................... 668 How to See Pre-defined Monitoring Information............................................................................................. 671 How to Examine Self-Define Monitor Information............................................................................................ 681 Abnormality Record Menu................................................................................................................... 696 How to See Maintenance Record............................................................................................................. 700 Maintenance Mode Setting.................................................................................................................. 701 How to Set Phone Number Entry............................................................................................................. 705 Default Menu.............................................................................................................................. 707 Diagnostic Tests Menu..................................................................................................................... 717 Adjustment Menu........................................................................................................................... 729 No-Injection Cranking Operation........................................................................................................... 747 Machine Configuration Menu................................................................................................................ 749 KOMTRAX Settings Menu..................................................................................................................... 752 How to Show Service Message............................................................................................................... 754 How to Operate Snap Shot.................................................................................................................. 755 How to Start Up KOMTRAX Terminal.............................................................................................................. 757 How to Stop Use of KOMTRAX Terminal........................................................................................................... 762 Default Setting of KOMTRAX Plus Controller.................................................................................................... 764 How to do the Default Setting of KOMTRAX Plus Controller.................................................................................. 764 Default Setting of Wireless LAN Modem......................................................................................................... 767 Default Setting of Wireless LAN Modem..................................................................................................... 767 How to Examine Wireless LAN Modem Communication........................................................................................... 768 Download Data from KOMTRAX Plus Controller.................................................................................................... 770 How to Download Data from KOMTRAX Plus Controller......................................................................................... 770 Adjust After Replacement of KOMTRAX Plus Controller........................................................................................... 773 How to Adjust After Replacement of KOMTRAX Plus Controller................................................................................ 773 Adjust After Replacement of Wireless LAN Modem................................................................................................ 776 How to Adjust After Replacement of Wireless LAN Modem..................................................................................... 776 Adjust KomVision Camera Angle................................................................................................................. 779 How to Adjust KomVision Camera Angle...................................................................................................... 779 Handle Voltage Circuit of Engine Controller................................................................................................... 782 Handle Battery Isolator and Starting Motor Isolator........................................................................................... 783 Examine Diodes................................................................................................................................ 784 How to Examine Diodes by Digital Tester................................................................................................... 784 How to Examine Diodes by Analog Tester.................................................................................................... 784 Pm Clinic......................................................................................................................................... 785 Pm Clinic Service............................................................................................................................. 785 Pm Clinic Check Sheet: PC2000-11E0 (Backhoe Specification)................................................................................ 790 Pm Clinic Check Sheet: PC2000-11E0 (Loading Shovel Specification)......................................................................... 803 Perform Quick Pm.............................................................................................................................. 817 How to Perform Quick Pm................................................................................................................... 817 40 Troubleshooting.................................................................................................................................... 823 Table of Contents................................................................................................................................. 824 Precautions Before Work........................................................................................................................... 837 Related Information to Troubleshooting............................................................................................................ 838 General Troubleshooting Points................................................................................................................ 838 Troubleshooting Points for Aftertreatment System.............................................................................................. 839 Sequence of Events in Troubleshooting......................................................................................................... 848 Checks Before Troubleshooting................................................................................................................. 850 Inspection Procedure Before Troubleshooting................................................................................................... 852 Walk-Around Check......................................................................................................................... 852 Test in Accordance with Testing Procedure..................................................................................................... 854 Examine Fuel Level and Type............................................................................................................... 854 Examine for Impure Ingredient in Fuel..................................................................................................... 854 Examine Fuel Prefilter.................................................................................................................... 855 Examine Water Separator, Drain Water and Sediment......................................................................................... 855 Replace Fuel Prefilter Cartridge.......................................................................................................... 856 Examine Fuel Main Filter.................................................................................................................. 857 Examine Engine Oil Level (Oil Quantity in Oil Pan)........................................................................................ 859 Examine Coolant Level (Reservoir Tank).................................................................................................... 861 Examine Air Cleaner Clogging.............................................................................................................. 861 Clean Outer Element....................................................................................................................... 861 Replace Element........................................................................................................................... 864 Examine Hydraulic Oil Level............................................................................................................... 864 Examine Hydraulic Oil Strainer............................................................................................................ 866 Examine Hydraulic Oil Filter.............................................................................................................. 866 Examine Oil Level in Swing Machinery Case................................................................................................. 867 Examine Oil Level in PTO Case............................................................................................................. 869 Examine PTO Lubrication Filter Strainer................................................................................................... 869 Examine Oil Level in Final Drive Case..................................................................................................... 870 Bleed Air from Fuel System................................................................................................................ 870 Bleed Air from Hydraulic System........................................................................................................... 870 How to Examine Electric Equipment......................................................................................................... 870 Preparation for Troubleshooting of Electrical System.......................................................................................... 876 Preparation for Troubleshooting of Machine Monitor........................................................................................ 876 Preparation for Troubleshooting of Engine Controller...................................................................................... 876 Preparation for Troubleshooting of Pump Controller........................................................................................ 876 Preparation for Troubleshooting of KOMTRAX Plus Controller................................................................................ 877 Preparation for Troubleshooting of KomVision Controller................................................................................... 877 How to Disconnect and Connect Connector with a Special Lock............................................................................... 877 Procedure for Troubleshooting................................................................................................................. 882 Symptom and Troubleshooting Numbers........................................................................................................... 885 Information Shown in Troubleshooting Table.................................................................................................... 890 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness............................................................... 892 Connector List and Layout..................................................................................................................... 895 Connector Contact Connection Table............................................................................................................ 918 T-Branch Box and T-Branch Adapter Table....................................................................................................... 960 Fuse Location Table........................................................................................................................... 966 Precautions When You Clean and Replace KDPF (KCSF and KDOC)................................................................................... 973 Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])................................................. 977 Failure Code Table............................................................................................................................ 979 Troubleshooting by Failure Code (Display of Code).................................................................................................1004 Failure Code [7@HAZL].........................................................................................................................1004 Failure Code [7@HBZL].........................................................................................................................1006 Failure Code [7@HCZL].........................................................................................................................1007 Failure Code [7@HDZL].........................................................................................................................1008 Failure Code [8800ZG].........................................................................................................................1009 Failure Code [989L00].........................................................................................................................1010 Failure Code [989M00].........................................................................................................................1011 Failure Code [989N00].........................................................................................................................1012 Failure Code [A1U0N3].........................................................................................................................1013 Failure Code [A1U0N4].........................................................................................................................1015 Failure Code [A900FR].........................................................................................................................1017 Failure Code [A900N6].........................................................................................................................1018 Failure Code [A900NY].........................................................................................................................1019 Failure Code [AA10NX].........................................................................................................................1020 Failure Code [AQ10N3].........................................................................................................................1021 Failure Code [AS00R2].........................................................................................................................1022 Failure Code [AS00R3].........................................................................................................................1023 Failure Code [AS00R4].........................................................................................................................1024 Failure Code [AS00R6].........................................................................................................................1025 Failure Code [B@BAZG].........................................................................................................................1026 Failure Code [B@BAZK].........................................................................................................................1027 Failure Code [B@BCNS].........................................................................................................................1028 Failure Code [B@BCQA].........................................................................................................................1029 Failure Code [B@BCZK].........................................................................................................................1031 Failure Code [B@HANS].........................................................................................................................1033 Failure Code [B@HAZK].........................................................................................................................1034 Failure Code [CA115]..........................................................................................................................1035 Failure Code [CA122]..........................................................................................................................1039 Failure Code [CA123]..........................................................................................................................1041 Failure Code [CA131]..........................................................................................................................1043 Failure Code [CA132]..........................................................................................................................1045 Failure Code [CA135]..........................................................................................................................1047 Failure Code [CA141]..........................................................................................................................1049 Failure Code [CA144]..........................................................................................................................1051 Failure Code [CA145]..........................................................................................................................1053 Failure Code [CA153]..........................................................................................................................1055 Failure Code [CA154]..........................................................................................................................1058 Failure Code [CA187]..........................................................................................................................1061 Failure Code [CA212]..........................................................................................................................1063 Failure Code [CA213]..........................................................................................................................1065 Failure Code [CA221]..........................................................................................................................1067 Failure Code [CA222]..........................................................................................................................1069 Failure Code [CA227]..........................................................................................................................1071 Failure Code [CA234]..........................................................................................................................1073 Failure Code [CA238]..........................................................................................................................1074 Failure Code [CA239]..........................................................................................................................1076 Failure Code [CA271]..........................................................................................................................1078 Failure Code [CA272]..........................................................................................................................1080 Failure Code [CA273]..........................................................................................................................1081 Failure Code [CA274]..........................................................................................................................1083 Failure Code [CA322]..........................................................................................................................1084 Failure Code [CA323]..........................................................................................................................1086 Failure Code [CA324]..........................................................................................................................1088 Failure Code [CA325]..........................................................................................................................1090 Failure Code [CA331]..........................................................................................................................1092 Failure Code [CA332]..........................................................................................................................1094 Failure Code [CA343]..........................................................................................................................1096 Failure Code [CA351]..........................................................................................................................1104 Failure Code [CA352]..........................................................................................................................1106 Failure Code [CA356]..........................................................................................................................1108 Failure Code [CA357]..........................................................................................................................1110 Failure Code [CA386]..........................................................................................................................1112 Failure Code [CA441]..........................................................................................................................1114 Failure Code [CA442]..........................................................................................................................1116 Failure Code [CA449]..........................................................................................................................1118 Failure Code [CA451]..........................................................................................................................1119 Failure Code [CA452]..........................................................................................................................1121 Failure Code [CA515]..........................................................................................................................1123 Failure Code [CA516]..........................................................................................................................1124 Failure Code [CA553]..........................................................................................................................1125 Failure Code [CA555]..........................................................................................................................1126 Failure Code [CA556]..........................................................................................................................1128 Failure Code [CA559]..........................................................................................................................1130 Failure Code [CA595]..........................................................................................................................1136 Failure Code [CA687]..........................................................................................................................1138 Failure Code [CA689]..........................................................................................................................1140 Failure Code [CA691]..........................................................................................................................1142 Failure Code [CA692]..........................................................................................................................1144 Failure Code [CA697]..........................................................................................................................1146 Failure Code [CA698]..........................................................................................................................1147 Failure Code [CA731]..........................................................................................................................1148 Failure Code [CA778]..........................................................................................................................1152 Failure Code [CA1117].........................................................................................................................1155 Failure Code [CA1135].........................................................................................................................1157 Failure Code [CA1257].........................................................................................................................1160 Failure Code [CA1664].........................................................................................................................1161 Failure Code [CA1691].........................................................................................................................1163 Failure Code [CA1695].........................................................................................................................1166 Failure Code [CA1696].........................................................................................................................1168 Failure Code [CA1843].........................................................................................................................1170 Failure Code [CA1844].........................................................................................................................1172 Failure Code [CA1879].........................................................................................................................1174 Failure Code [CA1881].........................................................................................................................1176 Failure Code [CA1883].........................................................................................................................1178 Failure Code [CA1921].........................................................................................................................1181 Failure Code [CA1922].........................................................................................................................1183 Failure Code [CA1923].........................................................................................................................1186 Failure Code [CA1924].........................................................................................................................1188 Failure Code [CA1925].........................................................................................................................1191 Failure Code [CA1927].........................................................................................................................1193 Failure Code [CA1928].........................................................................................................................1195 Failure Code [CA1942].........................................................................................................................1197 Failure Code [CA1963].........................................................................................................................1199 Failure Code [CA1977].........................................................................................................................1203 Failure Code [CA1993].........................................................................................................................1205 Failure Code [CA2185].........................................................................................................................1207 Failure Code [CA2186].........................................................................................................................1209 Failure Code [CA2249].........................................................................................................................1211 Failure Code [CA2265].........................................................................................................................1216 Failure Code [CA2266].........................................................................................................................1218 Failure Code [CA2271].........................................................................................................................1220 Failure Code [CA2272].........................................................................................................................1222 Failure Code [CA2349].........................................................................................................................1224 Failure Code [CA2353].........................................................................................................................1226 Failure Code [CA2357].........................................................................................................................1228 Failure Code [CA2381].........................................................................................................................1231 Failure Code [CA2382].........................................................................................................................1233 Failure Code [CA2383].........................................................................................................................1235 Failure Code [CA2386].........................................................................................................................1237 Failure Code [CA2387].........................................................................................................................1239 Failure Code [CA2555].........................................................................................................................1242 Failure Code [CA2556].........................................................................................................................1244 Failure Code [CA2637].........................................................................................................................1246 Failure Code [CA2639].........................................................................................................................1248 Failure Code [CA2732].........................................................................................................................1250 Failure Code [CA2733].........................................................................................................................1252 Failure Code [CA2741].........................................................................................................................1254 Failure Code [CA2765].........................................................................................................................1256 Failure Code [CA2777].........................................................................................................................1257 Failure Code [CA2878].........................................................................................................................1259 Failure Code [CA2881].........................................................................................................................1262 Failure Code [CA3133].........................................................................................................................1266 Failure Code [CA3134].........................................................................................................................1268 Failure Code [CA3135].........................................................................................................................1270 Failure Code [CA3167].........................................................................................................................1273 Failure Code [CA3251].........................................................................................................................1276 Failure Code [CA3253].........................................................................................................................1278 Failure Code [CA3254].........................................................................................................................1283 Failure Code [CA3255].........................................................................................................................1286 Failure Code [CA3256].........................................................................................................................1289 Failure Code [CA3311].........................................................................................................................1291 Failure Code [CA3312].........................................................................................................................1293 Failure Code [CA3313].........................................................................................................................1295 Failure Code [CA3314].........................................................................................................................1296 Failure Code [CA3315].........................................................................................................................1297 Failure Code [CA3316].........................................................................................................................1300 Failure Code [CA3317].........................................................................................................................1301 Failure Code [CA3318].........................................................................................................................1302 Failure Code [CA3319].........................................................................................................................1305 Failure Code [CA3321].........................................................................................................................1306 Failure Code [CA3322].........................................................................................................................1307 Failure Code [CA3419].........................................................................................................................1310 Failure Code [CA3421].........................................................................................................................1312 Failure Code [CA4151].........................................................................................................................1314 Failure Code [CA4158].........................................................................................................................1317 Failure Code [CA4161].........................................................................................................................1318 Failure Code [CA4162].........................................................................................................................1320 Failure Code [CA4163].........................................................................................................................1322 Failure Code [CA4259].........................................................................................................................1324 Failure Code [CA4952].........................................................................................................................1327 Failure Code [CA5383].........................................................................................................................1329 Failure Code [CB115]..........................................................................................................................1330 Failure Code [CB123]..........................................................................................................................1334 Failure Code [CB153]..........................................................................................................................1336 Failure Code [CB154]..........................................................................................................................1339 Failure Code [CB187]..........................................................................................................................1342 Failure Code [CB227]..........................................................................................................................1344 Failure Code [CB238]..........................................................................................................................1346 Failure Code [CB239]..........................................................................................................................1348 Failure Code [CB271]..........................................................................................................................1350 Failure Code [CB272]..........................................................................................................................1352 Failure Code [CB273]..........................................................................................................................1353 Failure Code [CB274]..........................................................................................................................1355 Failure Code [CB343]..........................................................................................................................1356 Failure Code [CB351]..........................................................................................................................1358 Failure Code [CB352]..........................................................................................................................1360 Failure Code [CB356]..........................................................................................................................1362 Failure Code [CB357]..........................................................................................................................1364 Failure Code [CB386]..........................................................................................................................1366 Failure Code [CB441]..........................................................................................................................1368 Failure Code [CB442]..........................................................................................................................1370 Failure Code [CB449]..........................................................................................................................1372 Failure Code [CB451]..........................................................................................................................1373 Failure Code [CB452]..........................................................................................................................1375 Failure Code [CB515]..........................................................................................................................1377 Failure Code [CB516]..........................................................................................................................1378 Failure Code [CB553]..........................................................................................................................1379 Failure Code [CB555]..........................................................................................................................1380 Failure Code [CB556]..........................................................................................................................1382 Failure Code [CB559]..........................................................................................................................1384 Failure Code [CB595]..........................................................................................................................1389 Failure Code [CB687]..........................................................................................................................1391 Failure Code [CB689]..........................................................................................................................1393 Failure Code [CB691]..........................................................................................................................1395 Failure Code [CB692]..........................................................................................................................1397 Failure Code [CB697]..........................................................................................................................1399 Failure Code [CB698]..........................................................................................................................1400 Failure Code [CB731]..........................................................................................................................1401 Failure Code [CB778]..........................................................................................................................1405 Failure Code [CB1117].........................................................................................................................1408 Failure Code [CB1257].........................................................................................................................1410 Failure Code [CB1548].........................................................................................................................1411 Failure Code [CB1549].........................................................................................................................1413 Failure Code [CB1551].........................................................................................................................1415 Failure Code [CB1552].........................................................................................................................1417 Failure Code [CB1553].........................................................................................................................1419 Failure Code [CB1622].........................................................................................................................1421 Failure Code [CB1664].........................................................................................................................1423 Failure Code [CB1691].........................................................................................................................1425 Failure Code [CB1695].........................................................................................................................1428 Failure Code [CB1696].........................................................................................................................1430 Failure Code [CB1843].........................................................................................................................1432 Failure Code [CB1844].........................................................................................................................1434 Failure Code [CB1879].........................................................................................................................1436 Failure Code [CB1881].........................................................................................................................1438 Failure Code [CB1883].........................................................................................................................1440 Failure Code [CB1921].........................................................................................................................1443 Failure Code [CB1922].........................................................................................................................1445 Failure Code [CB1923].........................................................................................................................1448 Failure Code [CB1924].........................................................................................................................1450 Failure Code [CB1925].........................................................................................................................1453 Failure Code [CB1927].........................................................................................................................1455 Failure Code [CB1928].........................................................................................................................1457 Failure Code [CB1942].........................................................................................................................1459 Failure Code [CB1963].........................................................................................................................1461 Failure Code [CB1977].........................................................................................................................1466 Failure Code [CB1993].........................................................................................................................1468 Failure Code [CB2249].........................................................................................................................1470 Failure Code [CB2265].........................................................................................................................1475 Failure Code [CB2266].........................................................................................................................1477 Failure Code [CB2271].........................................................................................................................1479 Failure Code [CB2272].........................................................................................................................1481 Failure Code [CB2349].........................................................................................................................1483 Failure Code [CB2353].........................................................................................................................1485 Failure Code [CB2357].........................................................................................................................1487 Failure Code [CB2381].........................................................................................................................1490 Failure Code [CB2382].........................................................................................................................1492 Failure Code [CB2383].........................................................................................................................1494 Failure Code [CB2386].........................................................................................................................1496 Failure Code [CB2387].........................................................................................................................1498 Failure Code [CB2637].........................................................................................................................1501 Failure Code [CB2639].........................................................................................................................1503 Failure Code [CB2732].........................................................................................................................1505 Failure Code [CB2733].........................................................................................................................1507 Failure Code [CB2741].........................................................................................................................1509 Failure Code [CB2765].........................................................................................................................1511 Failure Code [CB2777].........................................................................................................................1512 Failure Code [CB2878].........................................................................................................................1514 Failure Code [CB2881].........................................................................................................................1517 Failure Code [CB3313].........................................................................................................................1521 Failure Code [CB3133].........................................................................................................................1522 Failure Code [CB3134].........................................................................................................................1524 Failure Code [CB3135].........................................................................................................................1526 Failure Code [CB3167].........................................................................................................................1529 Failure Code [CB3251].........................................................................................................................1532 Failure Code [CB3253].........................................................................................................................1534 Failure Code [CB3254].........................................................................................................................1539 Failure Code [CB3255].........................................................................................................................1542 Failure Code [CB3256].........................................................................................................................1545 Failure Code [CB3311].........................................................................................................................1547 Failure Code [CB3312].........................................................................................................................1549 Failure Code [CB3313].........................................................................................................................1551 Failure Code [CB3314].........................................................................................................................1552 Failure Code [CB3315].........................................................................................................................1553 Failure Code [CB3316].........................................................................................................................1556 Failure Code [CB3317].........................................................................................................................1557 Failure Code [CB3318].........................................................................................................................1558 Failure Code [CB3319].........................................................................................................................1561 Failure Code [CB3321].........................................................................................................................1562 Failure Code [CB3322].........................................................................................................................1563 Failure Code [CB3419].........................................................................................................................1566 Failure Code [CB3421].........................................................................................................................1568 Failure Code [CB4151].........................................................................................................................1570 Failure Code [CB4158].........................................................................................................................1574 Failure Code [CB4161].........................................................................................................................1575 Failure Code [CB4162].........................................................................................................................1577 Failure Code [CB4163].........................................................................................................................1579 Failure Code [CB4259].........................................................................................................................1582 Failure Code [CB4952].........................................................................................................................1585 Failure Code [CB5383].........................................................................................................................1587 Failure Code [D110KB].........................................................................................................................1588 Failure Code [D163KB].........................................................................................................................1590 Failure Code [D195KA].........................................................................................................................1592 Failure Code [D195KB].........................................................................................................................1595 Failure Code [D19JKZ].........................................................................................................................1597 Failure Code [D1E7KA].........................................................................................................................1599 Failure Code [D1E7KB].........................................................................................................................1600 Failure Code [D1E7KY].........................................................................................................................1601 Failure Code [D1E9KB].........................................................................................................................1602 Failure Code [D1EAKB].........................................................................................................................1605 Failure Code [D1EBKB].........................................................................................................................1607 Failure Code [D1ECKB].........................................................................................................................1610 Failure Code [D1EJKA].........................................................................................................................1612 Failure Code [D1EJKB].........................................................................................................................1614 Failure Code [D1EKKA].........................................................................................................................1616 Failure Code [D1EKKB].........................................................................................................................1618 Failure Code [D1ELKA].........................................................................................................................1620 Failure Code [D1ELKB].........................................................................................................................1622 Failure Code [D1F0KA].........................................................................................................................1624 Failure Code [D1F0KB].........................................................................................................................1625 Failure Code [D1F0KY].........................................................................................................................1626 Failure Code [D8AQKR].........................................................................................................................1627 Failure Code [DA20MC].........................................................................................................................1631 Failure Code [DA22KK].........................................................................................................................1632 Failure Code [DA25KP].........................................................................................................................1635 Failure Code [DA26KP].........................................................................................................................1637 Failure Code [DA29KQ] (Backhoe Specification).................................................................................................1639 Failure Code [DA29KQ] (Loading Shovel Specification)..........................................................................................1641 Failure Code [DA2LKA].........................................................................................................................1643 Failure Code [DA2LKB].........................................................................................................................1646 Failure Code [DA2QKR].........................................................................................................................1648 Failure Code [DA2RKR].........................................................................................................................1654 Failure Code [DAF0KM].........................................................................................................................1659 Failure Code [DAF0MB].........................................................................................................................1660 Failure Code [DAF0MC].........................................................................................................................1661 Failure Code [DAF9KQ].........................................................................................................................1662 Failure Code [DAFGMC].........................................................................................................................1663 Failure Code [DAFLKA].........................................................................................................................1664 Failure Code [DAFLKB].........................................................................................................................1667 Failure Code [DAFQKR].........................................................................................................................1669 Failure Code [DB2QKR].........................................................................................................................1674 Failure Code [DB2RKR].........................................................................................................................1684 Failure Code [DBP0KM].........................................................................................................................1693 Failure Code [DBP0KT].........................................................................................................................1694 Failure Code [DBP0MC].........................................................................................................................1695 Failure Code [DBP0NR].........................................................................................................................1696 Failure Code [DBP5KP] (Applicable Machine: 30015 to 30157)....................................................................................1697 Failure Code [DBP5KP] (Applicable Machine: 30158 and up)......................................................................................1700 Failure Code [DBPLKA].........................................................................................................................1703 Failure Code [DBPLKB].........................................................................................................................1706 Failure Code [DBPQKR] (Applicable Machine: 30015 to 30157)....................................................................................1708 Failure Code [DBPQKR] (Applicable Machine: 30158 and up)......................................................................................1713 Failure Code [DBPUKR].........................................................................................................................1718 Failure Code [DBPVKR].........................................................................................................................1728 Failure Code [DBV0MC].........................................................................................................................1738 Failure Code [DBV1KK].........................................................................................................................1739 Failure Code [DBV5KB].........................................................................................................................1741 Failure Code [DBV6KB].........................................................................................................................1743 Failure Code [DBV8KB].........................................................................................................................1745 Failure Code [DBVLKA].........................................................................................................................1750 Failure Code [DBVLKB].........................................................................................................................1752 Failure Code [[DBVQKR]........................................................................................................................1754 Failure Code [DBVRKR].........................................................................................................................1758 Failure Code [DBVVKR].........................................................................................................................1762 Failure Code [DBVWKR].........................................................................................................................1763 Failure Code [DBWQKR].........................................................................................................................1764 Failure Code [DBWRKR].........................................................................................................................1770 Failure Code [DBX0MC].........................................................................................................................1776 Failure Code [DBX2KK].........................................................................................................................1777 Failure Code [DBX5KP].........................................................................................................................1779 Failure Code [DBX6KP].........................................................................................................................1781 Failure Code [DBX9KQ] (Backhoe Specification).................................................................................................1783 Failure Code [DBX9KQ] (Loading Shovel Specification)..........................................................................................1785 Failure Code [DBXLKA].........................................................................................................................1787 Failure Code [DBXLKB].........................................................................................................................1790 Failure Code [DBXQKR].........................................................................................................................1792 Failure Code [DBXRKR].........................................................................................................................1798 Failure Code [DBY0MC].........................................................................................................................1804 Failure Code [DBY2KK].........................................................................................................................1805 Failure Code [DBY5KP].........................................................................................................................1807 Failure Code [DBY6KP].........................................................................................................................1809 Failure Code [DBY9KQ] (Backhoe Specification).................................................................................................1811 Failure Code [DBY9KQ] (Loading Shovel Specification)..........................................................................................1813 Failure Code [DBYLKA].........................................................................................................................1815 Failure Code [DBYLKB].........................................................................................................................1818 Failure Code [DDNRKA].........................................................................................................................1820 Failure Code [DDNRKY].........................................................................................................................1822 Failure Code [DDNS00].........................................................................................................................1824 Failure Code [DDXAL4].........................................................................................................................1826 Failure Code [DGE5KB].........................................................................................................................1828 Failure Code [DGH2KA].........................................................................................................................1830 Failure Code [DGH2KB].........................................................................................................................1832 Failure Code [DGT3KB].........................................................................................................................1834 Failure Code [DGT5KA].........................................................................................................................1836 Failure Code [DGT5KB].........................................................................................................................1838 Failure Code [DGT6KA].........................................................................................................................1840 Failure Code [DGT6KB].........................................................................................................................1842 Failure Code [DH25MA].........................................................................................................................1844 Failure Code [DH26MA].........................................................................................................................1846 Failure Code [DH27MA].........................................................................................................................1848 Failure Code [DH28MA].........................................................................................................................1850 Failure Code [DHA4KA].........................................................................................................................1852 Failure Code [DHA5KA].........................................................................................................................1853 Failure Code [DHAAMA].........................................................................................................................1854 Failure Code [DHABMA].........................................................................................................................1855 Failure Code [DHACMA].........................................................................................................................1856 Failure Code [DHADMA].........................................................................................................................1857 Failure Code [DHPEMA].........................................................................................................................1858 Failure Code [DHPFMA].........................................................................................................................1860 Failure Code [DHPGMA].........................................................................................................................1862 Failure Code [DHPSMA].........................................................................................................................1864 Failure Code [DHPHMA].........................................................................................................................1866 Failure Code [DHPTMA].........................................................................................................................1868 Failure Code [DHPUMA].........................................................................................................................1870 Failure Code [DHS3MA].........................................................................................................................1872 Failure Code [DHS4MA].........................................................................................................................1875 Failure Code [DHS8MA].........................................................................................................................1878 Failure Code [DHS9MA].........................................................................................................................1881 Failure Code [DHSAMA].........................................................................................................................1884 Failure Code [DHSBMA].........................................................................................................................1887 Failure Code [DHSCMA].........................................................................................................................1890 Failure Code [DHSDMA].........................................................................................................................1893 Failure Code [DHSFMA].........................................................................................................................1896 Failure Code [DHSGMA].........................................................................................................................1899 Failure Code [DHSHMA].........................................................................................................................1902 Failure Code [DHSJMA].........................................................................................................................1905 Failure Code [DKR0MA].........................................................................................................................1908 Failure Code [DKR1MA].........................................................................................................................1911 Failure Code [DKR2KA].........................................................................................................................1914 Failure Code [DKR2KB].........................................................................................................................1915 Failure Code [DKR2NX].........................................................................................................................1916 Failure Code [DKR3KA].........................................................................................................................1918 Failure Code [DKR3KB].........................................................................................................................1919 Failure Code [DKR3NX].........................................................................................................................1920 Failure Code [DKR4KA].........................................................................................................................1922 Failure Code [DKR4KB].........................................................................................................................1923 Failure Code [DKR4NX].........................................................................................................................1924 Failure Code [DKR5MA].........................................................................................................................1926 Failure Code [DKR6MA].........................................................................................................................1929 Failure Code [[DKTKKX]........................................................................................................................1932 Failure Code [DKULKA].........................................................................................................................1934 Failure Code [DKULKB].........................................................................................................................1936 Failure Code [DKULKY].........................................................................................................................1938 Failure Code [DKVEL8].........................................................................................................................1940 Failure Code [DKVEMA].........................................................................................................................1942 Failure Code [DKVFL8].........................................................................................................................1944 Failure Code [DKVFMA].........................................................................................................................1946 Failure Code [DKVGL8].........................................................................................................................1948 Failure Code [DKVGMA].........................................................................................................................1950 Failure Code [DKVHL8].........................................................................................................................1952 Failure Code [DKVHMA].........................................................................................................................1954 Failure Code [DKVJL8].........................................................................................................................1956 Failure Code [DKVJMA].........................................................................................................................1958 Failure Code [DLM3KA].........................................................................................................................1960 Failure Code [DLM3KB].........................................................................................................................1962 Failure Code [DLM3MB].........................................................................................................................1964 Failure Code [DLM8KA].........................................................................................................................1968 Failure Code [DLM8KB].........................................................................................................................1969 Failure Code [DLM8MB].........................................................................................................................1970 Failure Code [DMU6KB].........................................................................................................................1971 Failure Code [DPQ1LD].........................................................................................................................1973 Failure Code [DPQ4KB].........................................................................................................................1974 Failure Code [DPQ4KT].........................................................................................................................1975 Failure Code [DR10KA].........................................................................................................................1976 Failure Code [DR20KA].........................................................................................................................1978 Failure Code [DR21KX].........................................................................................................................1980 Failure Code [DR30KA].........................................................................................................................1982 Failure Code [DR40KA].........................................................................................................................1984 Failure Code [DR50KA].........................................................................................................................1986 Failure Code [DR60KA].........................................................................................................................1988 Failure Code [DR90KA].........................................................................................................................1990 Failure Code [DV20KB].........................................................................................................................1992 Failure Code [DW45KA].........................................................................................................................1994 Failure Code [DW45KB].........................................................................................................................1997 Failure Code [DW45KY].........................................................................................................................2000 Failure Code [DW7BKA].........................................................................................................................2002 Failure Code [DW7BKB].........................................................................................................................2004 Failure Code [DW7BKY].........................................................................................................................2006 Failure Code [DW7HKA].........................................................................................................................2007 Failure Code [DW7HKB].........................................................................................................................2009 Failure Code [DW7HKY].........................................................................................................................2011 Failure Code [DWA5KA].........................................................................................................................2013 Failure Code [DWA5KB].........................................................................................................................2015 Failure Code [DWA5KY].........................................................................................................................2017 Failure Code [DWACKA].........................................................................................................................2018 Failure Code [DWACKB].........................................................................................................................2020 Failure Code [DWACKY].........................................................................................................................2022 Failure Code [DWK0KA].........................................................................................................................2023 Failure Code [DWK0KB].........................................................................................................................2025 Failure Code [DWK0KY].........................................................................................................................2027 Failure Code [DWK2KA].........................................................................................................................2029 Failure Code [DWK2KB].........................................................................................................................2031 Failure Code [DWK2KY].........................................................................................................................2033 Failure Code [DWM1KA].........................................................................................................................2035 Failure Code [DWM1KB].........................................................................................................................2037 Failure Code [DWM1KY].........................................................................................................................2039 Failure Code [DWN5KA].........................................................................................................................2041 Failure Code [DWN5KB].........................................................................................................................2042 Failure Code [DWNCKA].........................................................................................................................2043 Failure Code [DWNCKB].........................................................................................................................2044 Failure Code [DWNPKA].........................................................................................................................2045 Failure Code [DWNPKB].........................................................................................................................2047 Failure Code [DWNPKY].........................................................................................................................2049 Failure Code [DWNQKA].........................................................................................................................2050 Failure Code [DWNQKB].........................................................................................................................2052 Failure Code [DWNQKY].........................................................................................................................2054 Failure Code [DWNRKA].........................................................................................................................2055 Failure Code [DWNRKB].........................................................................................................................2057 Failure Code [DWNRKY].........................................................................................................................2059 Failure Code [DXR9KY].........................................................................................................................2061 Failure Code [DXAAKA].........................................................................................................................2062 Failure Code [DXAAKB].........................................................................................................................2064 Failure Code [DXABKA].........................................................................................................................2066 Failure Code [DXABKB].........................................................................................................................2068 Failure Code [DXACKA].........................................................................................................................2070 Failure Code [DXACKB].........................................................................................................................2072 Failure Code [DXADKA].........................................................................................................................2074 Failure Code [DXADKB].........................................................................................................................2076 Failure Code [DXR6KA].........................................................................................................................2078 Failure Code [DXR6KB].........................................................................................................................2079 Failure Code [DXR6KY].........................................................................................................................2080 Failure Code [DXR9KA].........................................................................................................................2081 Failure Code [DXR9KB].........................................................................................................................2082 Failure Code [DXR9KY].........................................................................................................................2083 Failure Code [DXRAKA].........................................................................................................................2084 Failure Code [DXRAKB].........................................................................................................................2085 Failure Code [DXRAKY].........................................................................................................................2086 Failure Code [DXRCKA].........................................................................................................................2087 Failure Code [DXRCKB].........................................................................................................................2088 Failure Code [DXRCKY].........................................................................................................................2089 Failure Code [DXRDKA].........................................................................................................................2090 Failure Code [DXRDKB].........................................................................................................................2091 Failure Code [DXRDKY].........................................................................................................................2092 Failure Code [DXRFKA].........................................................................................................................2093 Failure Code [DXRFKB].........................................................................................................................2094 Failure Code [DXRFKY].........................................................................................................................2095 Failure Code [DXRJKA].........................................................................................................................2096 Failure Code [DXRJKB].........................................................................................................................2097 Failure Code [DXRJKY].........................................................................................................................2098 Failure Code [DY20MA].........................................................................................................................2099 Failure Code [DY2CKA].........................................................................................................................2102 Failure Code [DY2CKY].........................................................................................................................2104 Failure Code [DY2FMA].........................................................................................................................2106 Failure Code [F@BYNR].........................................................................................................................2109 Failure Code [F@BYNS].........................................................................................................................2110 Failure Code [F@BZNR].........................................................................................................................2111 Failure Code [F@BZNS].........................................................................................................................2112 Failure Code [F7FQKR].........................................................................................................................2113 Failure Code [F7G0MC].........................................................................................................................2115 Failure Code [LA10ZL].........................................................................................................................2116 Failure Code [LA20ZL].........................................................................................................................2117 Troubleshooting of Electrical System (E-Mode).....................................................................................................2118 E-1 Engine Does Not Start (Engine Does Not Crank).............................................................................................2118 E-2 Manual Preheating System Does Not Operate.................................................................................................2127 E-3 Automatic Preheating System Does Not Operate..............................................................................................2130 E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On.....................................................................2132 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing..............................................................2134 E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow.........................2137 E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow...................2138 E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation..................................................................2139 E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs.....................................................................2140 E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs........................................................................2141 E-11 Charge Level Monitor Comes On in Red While Engine is in Operation........................................................................2142 E-12 Fuel Level Monitor Comes On in Red While Engine Runs.....................................................................................2143 E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation..........................................................2144 E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation.................................................................2145 E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation...........................................................2146 E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum.................................................................................2147 E-17 Display of Fuel Gauge is Different from Actual Fuel Level................................................................................2149 E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum..................................................................2150 E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature........................................................2151 E-20 Some Areas of Machine Monitor Screen are Not Shown.......................................................................................2152 E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum............................................................2153 E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature......................................................2155 E-23 Function Switch Does Not Operate.........................................................................................................2156 E-24 Automatic Warm-up System Does Not Work (in Cold Weather).................................................................................2157 E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out...................................2158 E-26 Auto-Decelerator is Not Operated or Canceled with Lever..................................................................................2159 E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown.........................................................2160 E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed........................................................2161 E-29 Service Meter is Not Shown, While Starting Switch is in OFF Position.....................................................................2162 E-30 Service Mode Cannot be Selected..........................................................................................................2163 E-31 All of Work Equipment, Swing, and Travel Mechanism Do Not Move...........................................................................2164 E-32 All Work Equipment, Swing and Travel Do Not Lock.........................................................................................2167 E-33 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing...........................................................2169 E-34 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate...........................................2171 E-35 Horn Does Not Sound......................................................................................................................2173 E-36 Horn Does Not Stop.......................................................................................................................2176 E-37 Alarm Does Not Sound During Travel.......................................................................................................2178 E-38 Alarm Does Not Stop When Machine Stops...................................................................................................2180 E-39 Alarm Buzzer Cannot be Canceled..........................................................................................................2181 E-40 Room Lamp, Headlamp, and Working Lamp Do Not Come On.....................................................................................2182 E-41 Headlamp or Working Lamp Does Not Come On................................................................................................2185 E-42 Room Lamp Does Not Come On...............................................................................................................2189 E-43 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out..................................................................2191 E-44 Wiper Does Not Operate When Wiper Switch is Operated (Upper Wiper Specification).........................................................2192 E-45 Wiper Does Not Operate When Wiper Switch is Operated (Lower Wiper Specification).........................................................2195 E-46 Fuel Feed Pump Does Not Operate or Stop Automatically....................................................................................2198 E-47 Window Washer Does Not Operate When Window Washer Switch is Operated.....................................................................2202 E-48 "Arm OUT" is Not Shown Correctly with Monitoring Function................................................................................2203 E-49 "Arm IN" is Not Shown Correctly with Monitoring Function.................................................................................2204 E-50 "Bucket DUMP" is Not Shown Correctly with Monitoring Function............................................................................2205 E-51 "Bucket CURL" is Not Shown Correctly with Monitoring Function............................................................................2206 E-52 "Swing" is Not Shown Correctly with Monitoring Function..................................................................................2207 E-53 "Travel” is Not Shown Correctly with Monitoring Function.................................................................................2208 E-54 "Boom RAISE" is Not Shown Correctly with Monitoring Function.............................................................................2209 E-55 "Boom LOWER" is Not Shown Correctly with Monitoring Function.............................................................................2210 E-56 KOMTRAX System Does Not Operate Correctly................................................................................................2211 E-57 Machine Push-Up Function is Not Canceled.................................................................................................2212 E-58 Machine Push-up Function Does Not Operate................................................................................................2214 E-59 Step Light Does Not Come On..............................................................................................................2215 E-60 Step Light Does Not Go Out...............................................................................................................2218 E-61 Boom Shockless Function Cannot be Canceled...............................................................................................2220 E-62 Boom Shockless Function Does Not Work....................................................................................................2222 E-63 Air Conditioner Control Panel Does Not Turn on...........................................................................................2223 E-64 Wind Does Not Come Out from the Air Conditioner..........................................................................................2225 E-65 Air Conditioner is Weak in Cold (Electric Capacitor Does Not Move or Only Hi Rotation Moves).............................................2227 E-66 Air Conditioner Does Not Get Cold (Compressor Does Not Move).............................................................................2229 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).....................................................................................2232 H-1 All Work Equipment, Swing and Travel Do Not Work..........................................................................................2232 H-2 All Work Equipment, Travel, Swing Speed or Power is Low...................................................................................2233 H-3 Engine Speed Drops Significantly or Engine Stalls.........................................................................................2235 H-4 Unusual Noise is Heard from Around Work Equipment Pump....................................................................................2236 H-5 Boom Speed or Power is Low in Normal Mode.................................................................................................2237 H-6 Boom RAISE Speed or Power is Low in Heavy Lift Mode.......................................................................................2238 H-7 Boom LOWER Speed or Power is Low in Machine Push Up Mode..................................................................................2239 H-8 Arm Speed or Power is Low.................................................................................................................2240 H-9 Bucket Speed or Power is Low..............................................................................................................2241 H-10 Boom Does Not Operate....................................................................................................................2242 H-11 Arm Does Not Operate.....................................................................................................................2243 H-12 Bucket Does Not Operate..................................................................................................................2244 H-13 Hydraulic Drift of Boom is Large.........................................................................................................2245 H-14 Hydraulic Drift of Arm is Large..........................................................................................................2246 H-15 Hydraulic Drift of Bucket is Large.......................................................................................................2247 H-16 Time Lag of Boom is Large................................................................................................................2248 H-17 Time Lag of Arm is Large.................................................................................................................2249 H-18 Time Lag of Bucket is Large..............................................................................................................2250 H-19 Boom Shockless Function Does Not Work or Cannot be Released..............................................................................2251 H-20 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Same Direction When Traveling Forward and Reverse)..........2252 H-21 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Different Directions When Traveling Forward and Reverse)....2254 H-22 Travel Deviation is Large at Start of Travel Only When Travel Lever is Fully Moved.......................................................2255 H-23 Regardless of the Stroke of the Travel Lever, Travel Deviation is Large at Start of Traveling............................................2256 H-24 Travel Deviation is Large at Mixed Operation.............................................................................................2257 H-25 Travel Speed or Power is Low.............................................................................................................2258 H-26 Only the One Side Track Can Operate (Machine Does Not Travel FORWARD or REVERSE).........................................................2259 H-27 Only the One Side Track Can Operate (in Either Forward or Reverse Direction).............................................................2260 H-28 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast........................................................................2261 H-29 Upper Structure Does Not Swing to Right and Left.........................................................................................2262 H-30 Upper Structure Swings Only to Right or Left.............................................................................................2263 H-31 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left)..........................................................2264 H-32 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction............................................2265 H-33 In Mixed Operation of Work Equipment, Swing Speed or Power is Low........................................................................2266 H-34 While Mixed Operation with Boom Swing Speed is Low or Swing Acceleration Performance is Unsatisfactory...................................2267 H-35 Upper Structure Overruns Too Much When It Stops Swing Operation in Lateral Directions of Right and Left..................................2268 H-36 Upper Structure Speed is High When It Stops Swing Operation (on One Side)................................................................2269 H-37 Shock is Large When Upper Structure Stops Swing Operation (Right and Left)...............................................................2270 H-38 Shock is Large When Upper Structure Stops Swing Operation (in Only Right of Left Direction)..............................................2271 H-39 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation (in Right and Left Directions)...................................2272 H-40 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation in Only One Direction............................................2273 H-41 Swing Drift on a Slope is Large..........................................................................................................2274 H-42 Fan Rotation is Abnormal (Such as Excessive Noise or Vibration of Fan, or Overheating)...................................................2275 H-43 Bottom Dump Speed is Low or Power is Low (Loading Shovel Specifications).................................................................2276 H-44 Bottom Dump Cylinder Dose Not Move (Loading Shovel Specifications).......................................................................2277 Troubleshooting of Engine (S-Mode)................................................................................................................2278 Information Shown in Troubleshooting Table (S-Mode)...........................................................................................2278 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position....................................................................2279 S-2 Engine Cranks but No Exhaust Smoke Comes Out..............................................................................................2280 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)..................................................2281 S-4 Engine Startability is Unsatisfactory.....................................................................................................2282 S-5 Engine Does Not Pick Up Smoothly..........................................................................................................2284 S-6 Engine Stops During Operation.............................................................................................................2286 S-7 Engine Runs Rough or is Not Stable........................................................................................................2288 S-8 Engine Lacks Power........................................................................................................................2289 S-9 KDPF Becomes Clogged in a Short Time......................................................................................................2291 S-10 Engine Oil Consumption is Excessive......................................................................................................2293 S-11 Oil Becomes Dirty Quickly................................................................................................................2294 S-12 Fuel Consumption is Excessive............................................................................................................2295 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant.....................................................................................2296 S-14 Oil Pressure Drops.......................................................................................................................2297 S-15 Fuel Mixes Into Engine Oil...............................................................................................................2299 S-16 Water Mixes Into Engine Oil (Milky)......................................................................................................2300 S-17 Coolant Temperature Increases Too High (Overheating).....................................................................................2301 S-18 Unusual Noise is Heard...................................................................................................................2303 S-19 Vibration is Excessive...................................................................................................................2304 S-20 Air Cannot be Bled from Fuel Circuit.....................................................................................................2305 S-21 Active Regeneration is Done Frequently...................................................................................................2306 S-22 Active Regeneration Continues Long.......................................................................................................2307 S-23 White Smoke is Exhausted During Active Regeneration......................................................................................2308 50 Disassembly and Assembly...........................................................................................................................2309 Table of Contents.................................................................................................................................2310 Precautions Before Work...........................................................................................................................2316 Related Information on Disassembly and Assembly...................................................................................................2317 How to Read This Manual.......................................................................................................................2317 Coating Materials List........................................................................................................................2319 Special Tool List.............................................................................................................................2324 Sketches of Special Tools.....................................................................................................................2342 Engine and Cooling System.........................................................................................................................2345 Remove and Install Supply Pump Assembly (Right Bank)..........................................................................................2345 How to Remove Supply Pump Assembly (Right Bank)...........................................................................................2345 How to Install Supply Pump Assembly (Right Bank)..........................................................................................2358 Remove and Install Supply Pump Assembly (Left Bank)...........................................................................................2380 How to Remove Supply Pump Assembly (Left Bank)............................................................................................2380 How to Install Supply Pump Assembly (Left Bank)...........................................................................................2389 Remove and Install Injector Assembly (Right Bank).............................................................................................2403 How to Remove Injector Assembly (Right Bank)..............................................................................................2403 How to Install Injector Assembly (Right Bank).............................................................................................2416 Remove and Install Injector Assembly (Left Bank)..............................................................................................2434 How to Remove Injector Assembly (Left Bank)...............................................................................................2434 How to Install Injector Assembly (Left Bank)..............................................................................................2448 Remove and Install Fuel Doser Assembly (Right Bank)...........................................................................................2467 How to Remove Fuel Doser Assembly (Right Bank)............................................................................................2467 How to Install Fuel Doser Assembly (Right Bank)...........................................................................................2470 Remove and Install Fuel Doser Assembly (Left Bank)............................................................................................2474 How to Remove Fuel Doser Assembly (Left Bank).............................................................................................2474 How to Install Fuel Doser Assembly (Left Bank)............................................................................................2477 Remove and Install Cylinder Head Assembly (Right Bank)........................................................................................2481 How to Remove Cylinder Head Assembly (Right Bank).........................................................................................2481 How to Install Cylinder Head Assembly (Right Bank)........................................................................................2515 Remove and Install Cylinder Head Assembly (Left Bank).........................................................................................2564 How to Remove Cylinder Head Assembly (Left Bank)..........................................................................................2564 How to Install Cylinder Head Assembly (Left Bank).........................................................................................2604 Remove and Install EGR Valve Assembly (Right Bank)............................................................................................2664 How to Remove EGR Valve Assembly (Right Bank).............................................................................................2664 How to Install EGR Valve Assembly (Right Bank)............................................................................................2676 Remove and Install EGR Valve Assembly (Left Bank).............................................................................................2692 How to Remove EGR Valve Assembly (Left Bank)..............................................................................................2692 How to Install EGR Valve Assembly (Left Bank).............................................................................................2704 Remove and Install EGR Cooler Assembly (Right Bank)...........................................................................................2722 How to Remove EGR Cooler Assembly (Right Bank)............................................................................................2722 How to Install EGR Cooler Assembly (Right Bank)...........................................................................................2743 Remove and Install EGR Cooler Assembly (Left Bank)............................................................................................2772 How to Remove EGR Cooler Assembly (Left Bank).............................................................................................2772 How to Install EGR Cooler Assembly (Left Bank)............................................................................................2790 Remove and Install Starter Assembly...........................................................................................................2816 How to Remove Starting Motor Assembly.....................................................................................................2816 How to Install Starting Motor Assembly....................................................................................................2819 Remove and Install Alternator Belt............................................................................................................2822 How to Remove Alternator Belt.............................................................................................................2822 How to Install Alternator Belt............................................................................................................2824 Remove and Install Alternator Assembly........................................................................................................2828 How to Remove Alternator Assembly.........................................................................................................2828 How to Install Alternator Assembly........................................................................................................2831 Remove and Install Radiator Assembly..........................................................................................................2838 How to Remove Radiator Assembly...........................................................................................................2838 How to Install Radiator Assembly..........................................................................................................2843 Remove and Install Hydraulic Oil Cooler Assembly..............................................................................................2849 How to Remove Hydraulic Oil Cooler Assembly...............................................................................................2849 How to Install Hydraulic Oil Cooler Assembly..............................................................................................2852 Remove and Install Aftercooler Assembly.......................................................................................................2856 How to Remove Aftercooler Assembly........................................................................................................2856 How to Install Aftercooler Assembly.......................................................................................................2861 Remove and Install Cooling Fan Motor Assembly.................................................................................................2867 How to Remove Cooling Fan Motor Assembly..................................................................................................2867 How to Install Cooling Fan Motor Assembly.................................................................................................2893 Remove and Install Power Module Packaging Assembly............................................................................................2918 How to Remove Power Module Packaging Assembly.............................................................................................2918 How to Install Power Module Packaging Assembly............................................................................................2933 Remove and Install Engine, PTO, and Hydraulic Pump Assembly...................................................................................2948 How to Remove Engine PTO and Hydraulic Assembly...........................................................................................2949 How to Install Engine PTO and Hydraulic Assembly..........................................................................................2981 Remove and Install Engine Front Oil Seal......................................................................................................3014 How to Remove Engine Front Oil Seal.......................................................................................................3014 How to Install Engine Front Oil Seal......................................................................................................3021 Remove and Install Engine Rear Oil Seal.......................................................................................................3029 How to Remove Engine Rear Oil Seal........................................................................................................3029 How to Install Engine Rear Oil Seal.......................................................................................................3031 Remove and Install Fuel Cooler Assembly.......................................................................................................3035 How to Remove Fuel Cooler Assembly........................................................................................................3035 How to Install Fuel Cooler Assembly.......................................................................................................3037 Remove and Install Engine Hood Assembly.......................................................................................................3039 How to Remove Engine Hood Assembly........................................................................................................3039 How to Install Engine Hood Assembly.......................................................................................................3044 Remove and Install Fuel Tank Assembly.........................................................................................................3050 How to Remove Fuel Tank Assembly..........................................................................................................3050 How to Install Fuel Tank Assembly.........................................................................................................3053 Remove and Install KDPF Assembly..............................................................................................................3057 How to Remove KDPF Assembly...............................................................................................................3057 How to Install KDPF Assembly..............................................................................................................3066 Remove and Install Bellows Pipe Assembly......................................................................................................3077 How to Remove Bellows Pipe Assembly.......................................................................................................3077 How to Install Bellows Pipe Assembly......................................................................................................3079 Remove and Install KCCV Assembly (Right Bank).................................................................................................3080 How to Remove KCCV Assembly (Right Bank)..................................................................................................3080 How to Install KCCV Assembly (Right Bank).................................................................................................3083 Remove and Install KCCV Assembly (Left Bank)..................................................................................................3087 How to Remove KCCV Assembly (Left Bank)...................................................................................................3087 How to Install KCCV Assembly (Left Bank)..................................................................................................3090 Remove and Install VGT Assembly (Right Bank)..................................................................................................3096 How to Remove VGT Assembly (Right Bank)...................................................................................................3096 How to Install VGT Assembly (Right Bank)..................................................................................................3110 Remove and Install VGT Assembly (Left Bank)...................................................................................................3126 How to Remove VGT Assembly (Left Bank)....................................................................................................3126 How to Install VGT Assembly (Left Bank)...................................................................................................3140 Remove and Install Air Cleaner Assembly.......................................................................................................3156 How to Remove Air Cleaner Assembly........................................................................................................3156 How to Install Air Cleaner Assembly.......................................................................................................3159 Remove and Install Air Conditioner Compressor Assembly........................................................................................3163 How to Remove Air Conditioner Compressor Assembly.........................................................................................3163 How to Install Air Conditioner Compressor Assembly........................................................................................3165 Remove and Install Air Conditioner Condenser Assembly.........................................................................................3169 How to Remove Air Conditioner Condenser Assembly..........................................................................................3169 How to Install Air Conditioner Condenser Assembly.........................................................................................3171 Power Train.......................................................................................................................................3175 Disassemble and Assemble PTO Assembly.........................................................................................................3175 How to Disassemble PTO Assembly...........................................................................................................3175 How to Assemble PTO Assembly..............................................................................................................3180 Remove and Install PTO Assembly...............................................................................................................3184 How to Remove PTO Assembly................................................................................................................3184 How to Install PTO Assembly...............................................................................................................3185 Remove and Install Travel Motor and Final Drive Assembly......................................................................................3186 How to Remove Travel Motor and Final Drive Assembly.......................................................................................3186 How to Install Travel Motor and Final Drive Assembly......................................................................................3190 Disassemble and Assemble Final Drive Assembly.................................................................................................3194 How to Disassemble Final Drive Assembly...................................................................................................3195 How to Assemble Final Drive Assembly......................................................................................................3201 Remove and Install Swing Motor and Swing Machinery Assembly...................................................................................3210 How to Remove Swing Motor and Swing Machinery Assembly....................................................................................3211 How to Install Swing Motor and Swing Machinery Assembly...................................................................................3218 Disassemble and Assemble Swing Machinery Assembly.............................................................................................3225 How to Disassemble Swing Machinery Assembly...............................................................................................3225 How to Assemble Swing Machinery Assembly..................................................................................................3231 Remove and Install Swing Circle Assembly......................................................................................................3238 How to Remove Swing Circle Assembly.......................................................................................................3238 How to Install Swing Circle Assembly......................................................................................................3238 Undercarriage and Frame...........................................................................................................................3240 Remove and Install Idler Assembly.............................................................................................................3240 How to Remove Idler Assembly..............................................................................................................3240 How to Install Idler Assembly.............................................................................................................3241 Remove and Install Track Roller Assembly......................................................................................................3242 How to Remove Track Roller Assembly.......................................................................................................3242 How to Install Track Roller Assembly......................................................................................................3243 Remove and Install Carrier Roller Assembly....................................................................................................3245 How to Remove Carrier Roller Assembly.....................................................................................................3245 How to Install Carrier Roller Assembly....................................................................................................3246 Separate and Connect Track Assembly...........................................................................................................3248 How to Separate Track Assembly............................................................................................................3248 How to Install Track Assembly.............................................................................................................3249 Disassemble and Assemble Idler Assembly.......................................................................................................3251 How to Disassemble Idler Assembly.........................................................................................................3251 How to Assemble Idler Assembly............................................................................................................3253 Disassemble and Assemble Idler Adjustment Cylinder Assembly...................................................................................3256 How to Disassemble Idler Adjustment Cylinder Assembly.....................................................................................3256 How to Assemble Idler Adjustment Cylinder Assembly........................................................................................3257 Disassemble and Assemble Track Roller Assembly................................................................................................3259 How to Disassemble Track Roller Assembly..................................................................................................3259 How to Assemble Track Roller Assembly.....................................................................................................3260 Disassemble and Assemble Carrier Roller Assembly..............................................................................................3262 How to Disassemble Carrier Roller Assembly................................................................................................3262 How to Assemble Carrier Roller Assembly...................................................................................................3263 Remove and Install Revolving Frame Assembly...................................................................................................3266 How to Remove Revolving Frame Assembly....................................................................................................3266 How to Install Revolving Frame Assembly...................................................................................................3270 Remove and Install Counterweight Assembly.....................................................................................................3274 How to Remove Counterweight Assembly......................................................................................................3274 How to Install Counterweight Assembly.....................................................................................................3276 Hydraulic System..................................................................................................................................3279 Remove and Install Center Swivel Joint Assembly...............................................................................................3279 How to Remove Center Swivel Joint Assembly................................................................................................3279 How to Install Center Swivel Joint Assembly...............................................................................................3281 Disassemble and Assemble Center Swivel Joint Assembly.........................................................................................3285 How to Disassemble Center Swivel Joint Assembly...........................................................................................3286 How to Assemble Center Swivel Joint Assembly..............................................................................................3287 Remove and Install Hydraulic Tank Assembly....................................................................................................3288 How to Remove Hydraulic Tank Assembly.....................................................................................................3288 How to Install Hydraulic Tank Assembly....................................................................................................3296 Remove and Install Hydraulic Pump Assembly....................................................................................................3304 How to Remove Hydraulic Pump Assembly.....................................................................................................3305 How to Install Hydraulic Pump Assembly....................................................................................................3323 Remove and Install Control Valve Assembly.....................................................................................................3342 How to Remove Control Valve Assembly......................................................................................................3343 How to Install Control Valve Assembly.....................................................................................................3356 Remove and Install Swing Motor Assembly.......................................................................................................3372 How to Remove Swing Motor Assembly........................................................................................................3372 How to Install Swing Motor Assembly.......................................................................................................3378 Disassemble and Assemble Work Equipment PPC Valve Assembly....................................................................................3384 How to Disassemble Work Equipment PPC Valve Assembly......................................................................................3384 How to Assemble Work Equipment PPC Valve Assembly.........................................................................................3384 Disassemble and Assemble Travel PPC Valve Assembly............................................................................................3387 How to Disassemble Travel PPC Valve Assembly..............................................................................................3387 How to Assemble Travel PPC Valve Assembly.................................................................................................3388 Disassemble and Assemble Grease Gun Assembly..................................................................................................3391 How to Disassemble Grease Gun Assembly....................................................................................................3391 How to Assemble Grease Gun Assembly.......................................................................................................3391 Remove and Install Grease Pump................................................................................................................3392 How to Remove Grease Pump.................................................................................................................3392 How to Install Grease Pump................................................................................................................3394 Disassemble and Assemble Grease Pump..........................................................................................................3396 How to Disassemble Grease Pump............................................................................................................3396 How to Assemble Grease Pump...............................................................................................................3399 Work Equipment....................................................................................................................................3404 Remove and Install Bucket Cylinder Assembly (Backhoe Specification)...........................................................................3404 How to Remove Bucket Cylinder Assembly (Backhoe Specification)............................................................................3404 How to Install Bucket Cylinder Assembly (Backhoe Specification)...........................................................................3406 Remove and Install Bucket Cylinder Assembly (Loading Shovel Specification)....................................................................3409 How to Remove Bucket Cylinder Assembly (Loading Shovel Specification).....................................................................3409 How to Install Bucket Cylinder Assembly (Loading Shovel Specification)....................................................................3410 Remove and Install Arm Cylinder Assembly (Backhoe Specification)..............................................................................3412 How to Remove Arm Cylinder Assembly (Backhoe Specification)...............................................................................3412 How to Install Arm Cylinder Assembly (Backhoe Specification)..............................................................................3414 Remove and Install Arm Cylinder Assembly (Loading Shovel Specification).......................................................................3417 How to Remove Arm Cylinder Assembly (Loading Shovel Specification)........................................................................3417 How to Install Arm Cylinder Assembly (Loading Shovel Specification).......................................................................3418 Remove and Install Boom Cylinder Assembly (Backhoe Specification).............................................................................3419 How to Remove Boom Cylinder Assembly (Backhoe Specification)..............................................................................3419 How to Install Boom Cylinder Assembly (Backhoe Specification).............................................................................3422 Remove and Install Boom Cylinder Assembly (Loading Shovel Specification)......................................................................3425 How to Remove Boom Cylinder Assembly (Loading Shovel Specification).......................................................................3425 How to Install Boom Cylinder Assembly (Loading Shovel Specification)......................................................................3426 Remove and Install Bucket Assembly (Backhoe Specification)....................................................................................3428 How to Remove Bucket Assembly (Backhoe Specification).....................................................................................3428 How to Install Bucket Assembly (Backhoe Specification)....................................................................................3430 Remove and Install Bucket Assembly (Loading Shovel Specification).............................................................................3433 How to Remove Bucket Assembly (Loading Shovel Specification)..............................................................................3433 How to Install Bucket Assembly (Loading Shovel Specification).............................................................................3434 Remove and Install Arm Assembly (Backhoe Specification).......................................................................................3437 How to Remove Arm Assembly (Backhoe Specification)........................................................................................3437 How to Install Arm Assembly (Backhoe Specification).......................................................................................3443 Remove and Install Arm Assembly (Loading Shovel Specification)................................................................................3448 How to Remove Arm Assembly (Loading Shovel Specification).................................................................................3448 How to Install Arm Assembly (Loading Shovel Specification)................................................................................3449 Remove and Install Boom Assembly (Backhoe Specification)......................................................................................3451 How to Remove Boom Assembly (Backhoe Specification).......................................................................................3451 How to Install Boom Assembly (Backhoe Specification)......................................................................................3454 Remove and Install Boom Assembly (Loading Shovel Specification)...............................................................................3458 How to Remove Boom Assembly (Loading Shovel Specification)................................................................................3458 How to Install Boom Assembly (Loading Shovel Specification)...............................................................................3460 Disassemble and Assemble Work Equipment Cylinder Assembly (Backhoe Specification).............................................................3463 How to Disassemble Work Equipment Cylinder Assembly (Backhoe Specification)...............................................................3464 How to Assemble Work Equipment Cylinder Assembly (Backhoe Specification)..................................................................3467 Remove and Install Bottom Dump Cylinder Assembly (Loading Shovel Specification)...............................................................3472 How to Remove Bottom Dump Cylinder Assembly (Loading Shovel Specification)................................................................3472 How to Install Bottom Dump Cylinder Assembly (Loading Shovel Specification)...............................................................3473 CAB Related Parts.................................................................................................................................3475 Remove and Install Operator Cab Assembly......................................................................................................3475 How to Remove Operator Cab Assembly.......................................................................................................3476 How to Install Operator Cab Assembly......................................................................................................3483 Remove and Install CAB Base...................................................................................................................3490 How to Remove Cab Base....................................................................................................................3490 How to Install Cab Base...................................................................................................................3494 Remove and Install Operator Cab Glass (Adhered Glass).........................................................................................3499 How to Remove Operator Cab Glass (Adhered Glass)..........................................................................................3500 How to Install Operator Cab Glass (Adhered Glass).........................................................................................3501 Remove and Install Operator Cab Glass (Assembling Type).......................................................................................3508 How to Remove Operator Cab Glass (Assembling Type)........................................................................................3508 How to Install Operator Cab Glass (Assembling Type).......................................................................................3510 Remove and Install Air Conditioner Unit Assembly..............................................................................................3512 How to Remove Air Conditioner Unit Assembly...............................................................................................3512 How to Install Air Conditioner Unit Assembly..............................................................................................3527 Remove and Install Operator Seat..............................................................................................................3540 How to Remove Operator Seat...............................................................................................................3540 How to Install Operator Seat..............................................................................................................3543 How to Remove and Install Seat Belt...........................................................................................................3546 How to Remove Seat Belt...................................................................................................................3546 How to Install Seatbelt...................................................................................................................3547 Remove and Install Front Wiper Assembly.......................................................................................................3549 How to Remove Front Wiper Assembly........................................................................................................3549 How to Install Front Wiper Assembly.......................................................................................................3553 Electrical System.................................................................................................................................3557 Remove and Install Engine Controller Assembly (Right Bank)....................................................................................3557 How to Remove Engine Controller Assembly (Right Bank).....................................................................................3557 How to Install Engine Controller Assembly (Right Bank)....................................................................................3558 Remove and Install Engine Controller Assembly (Left Bank).....................................................................................3561 How to Remove Engine Controller Assembly (Left Bank)......................................................................................3561 How to Install Engine Controller Assembly (Left Bank).....................................................................................3562 Remove and Install Pump Controller Assembly...................................................................................................3565 How to Remove Pump Controller Assembly....................................................................................................3565 How to Install Pump Controller Assembly...................................................................................................3566 Remove and Install KomVision Controller Assembly..............................................................................................3568 How to Remove KomVision Controller Assembly...............................................................................................3568 How to Install KomVision Controller Assembly..............................................................................................3569 Remove and Install Machine Monitor Assembly...................................................................................................3571 How to Remove Machine Monitor Assembly....................................................................................................3571 How to Install Machine Monitor Assembly...................................................................................................3574 Remove and Install Mass Air Flow and Temperature Sensor.......................................................................................3577 How to Remove Mass Air Flow and Temperature Sensor........................................................................................3577 How to Install Mass Air Flow and Temperature Sensor.......................................................................................3578 Remove and Install KCCV Crankcase Pressure Sensor (Right Bank)................................................................................3579 How to Remove KCCV Crankcase Pressure Sensor (Right Bank).................................................................................3579 How to Install KCCV Crankcase Pressure Sensor (Right Bank)................................................................................3580 Remove and Install KCCV Crankcase Pressure Sensor (Left Bank).................................................................................3582 How to Remove KCCV Crankcase Pressure Sensor (Left Bank)..................................................................................3582 How to Install KCCV Crankcase Pressure Sensor (Left Bank).................................................................................3583 Remove and Install KDPF Temperature Sensor....................................................................................................3585 How to Remove KDPF Temperature Sensor.....................................................................................................3585 How to Install KDPF Temperature Sensor....................................................................................................3591 Remove and Install KDPF Differential Pressure Sensor..........................................................................................3597 How to Remove KDPF Differential Pressure Sensor...........................................................................................3597 How to Install KDPF Differential Pressure Sensor..........................................................................................3602 Remove and Install KomVision Camera...........................................................................................................3607 How to Remove KomVision Camera............................................................................................................3607 How to Install KomVision Camera...........................................................................................................3611 Remove And Install KOMTRAX Plus Controller Assembly...........................................................................................3615 How to Remove KOMTRAX Plus Controller Assembly............................................................................................3615 How to Install KOMTRAX Plus Controller Assembly...........................................................................................3616 Remove and Install Wireless LAN Unit Assembly.................................................................................................3618 How to Remove Wireless LAN Unit Assembly..................................................................................................3618 How to Install Wireless LAN Unit Assembly.................................................................................................3620 60 Maintenance Standard...............................................................................................................................3623 Table of Contents.................................................................................................................................3624 Engine and Cooling System.........................................................................................................................3625 Maintenance Standard for Engine Mount.........................................................................................................3625 Maintenance Standard for PTO..................................................................................................................3626 Maintenance Standard for Cooling Fan Pump.....................................................................................................3628 Maintenance Standard for EPC Valve of Cooling Fan Pump....................................................................................3631 Maintenance Standard for Cooling Fan Motor....................................................................................................3632 Power Train.......................................................................................................................................3635 Maintenance Standard for Swing Circle.........................................................................................................3635 Maintenance Standard for Swing Machinery......................................................................................................3636 Maintenance Standard for Final Drive..........................................................................................................3638 Maintenance Standard for Sprocket.............................................................................................................3640 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing............................................................................3641 Undercarriage and Frame...........................................................................................................................3642 Maintenance Standard for Track Frame and Idler Cushion........................................................................................3642 Maintenance Standard for Idler................................................................................................................3645 Maintenance Standard for Track Roller.........................................................................................................3647 Maintenance Standard for Carrier Roller.......................................................................................................3648 Maintenance Standard for Track Shoes..........................................................................................................3650 Maintenance Standard for Double Shoes.........................................................................................................3653 Maintenance Standard for Triple Shoes.........................................................................................................3654 Hydraulic System..................................................................................................................................3655 Maintenance Standard for Main Pump............................................................................................................3655 Maintenance Standard for Main Pump Servo Valve............................................................................................3659 Maintenance Standard for Swing Motor..........................................................................................................3661 Maintenance Standard for Travel Motor.........................................................................................................3664 Maintenance Standard for Control Valve........................................................................................................3668 Maintenance Standard for Variable Back Pressure Valve.........................................................................................3702 Maintenance Standard for PPC Cut-off Valve....................................................................................................3703 Maintenance Standard for Suction Selector Valve...............................................................................................3707 Maintenance Standard for Work Equipment and Swing PPC Valve...................................................................................3709 Maintenance Standard for Travel PPC Valve.....................................................................................................3712 Maintenance Standard for Center Swivel Joint..................................................................................................3715 Work Equipment....................................................................................................................................3716 Maintenance Standard for Work Equipment Linkage...............................................................................................3716 Dimensions of Arm.........................................................................................................................3720 Dimensions of Bucket......................................................................................................................3722 Maintenance Standard for Boom Cylinder........................................................................................................3725 Maintenance Standard for Arm Cylinder.........................................................................................................3726 Maintenance Standard for Bucket Cylinder......................................................................................................3727 Maintenance Standard of Work Equipment Linkage (Loading Shovel Specification..................................................................3728 Maintenance Standard of Boom Cylinder (Loading Shovel Specification)..........................................................................3731 Maintenance Standard of Arm Cylinder (Loading Shovel Specification)...........................................................................3732 Maintenance Standard of Bucket Cylinder (Loading Shovel Specification)........................................................................3733 80 Appendix...........................................................................................................................................3735 Table of Contents.................................................................................................................................3736 Precautions Before Work...........................................................................................................................3739 Air Conditioner System............................................................................................................................3740 Precautions for Refrigerant...................................................................................................................3740 Air Conditioner Component.....................................................................................................................3741 Air Conditioner Component.....................................................................................................................3743 Specifications of Air Conditioner.............................................................................................................3745 Structure and Function of Refrigeration Cycle.................................................................................................3746 Outline of Refrigeration Cycle................................................................................................................3747 Component Parts of Air Conditioner System.........................................................................................................3749 Air Conditioner Unit..........................................................................................................................3749 Configuration Diagram of Air Conditioner Unit.............................................................................................3749 Function of Air Conditioner Unit..........................................................................................................3751 Function of Evaporator as Air Conditioner Unit Component..................................................................................3752 Function of Heater Core as Air Conditioner Unit Component.................................................................................3752 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component...............................................................3753 Function of Servo Motor as Air Conditioner Unit Component.................................................................................3753 Structure of Expansion Valve as Air Conditioner Unit Component............................................................................3754 Function of Expansion Valve as Air Conditioner Unit Component.............................................................................3754 Operate Expansion Valve as Air Conditioner Unit Component.................................................................................3754 Function of Dual Pressure Switch..........................................................................................................3755 Air Conditioner Controller....................................................................................................................3756 Structure of Air Conditioner Controller...................................................................................................3756 Compressor....................................................................................................................................3757 Structure of Compressor...................................................................................................................3757 Specifications of Compressor..............................................................................................................3757 Function of Compressor....................................................................................................................3757 Condenser.....................................................................................................................................3758 Structure of Condenser....................................................................................................................3758 Specifications of Condenser...............................................................................................................3758 Function of Condenser.....................................................................................................................3758 Receiver Drier................................................................................................................................3759 Structure of Receiver Dryer...............................................................................................................3759 Specifications of Receiver Dryer..........................................................................................................3759 Function of Receiver Dryer................................................................................................................3759 Air Conditioner Related Sensors...............................................................................................................3760 Function of Sunlight Sensor...............................................................................................................3760 Structure of Outside Temperature Sensor...................................................................................................3760 Function of Outside Air Temperature Sensor................................................................................................3760 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.......................................................................3761 Circuit Diagram and Configuration of Connector Pins of Air Conditioner............................................................................3763 System Diagram of Air Conditioner.................................................................................................................3765 Air Conditioner Control Panel.................................................................................................................3766 Structure of Air Conditioner Control Panel................................................................................................3766 Input and Output Signals of Air Conditioner Controller........................................................................................3767 Function of Air Conditioner Controller....................................................................................................3768 Locations of Air Conditioner Parts and Layout of Connectors.......................................................................................3769 Examine Air Leakage (Duct)........................................................................................................................3773 How to Examine Air Leakage (Duct).............................................................................................................3773 Examine Air Conditioner with Self-Diagnosis Function..............................................................................................3774 Examine Vent (Mode) Changeover....................................................................................................................3776 How to Examine Vent (Mode) Changeover.........................................................................................................3776 Examine Fresh/Recirc Air Changeover...............................................................................................................3780 How to Examine Fresh/Recirc Air Changeover....................................................................................................3780 Examine Sunlight Sensor...........................................................................................................................3781 How to Examine Sunlight Sensor................................................................................................................3781 Examine Refrigerant (Dual) Pressure Switch........................................................................................................3782 How to Examine Refrigerant (Dual) Pressure Switch.............................................................................................3782 Examine Relay.....................................................................................................................................3784 How to Examine Relay..........................................................................................................................3784 Air Conditioner Troubleshooting Chart 1...........................................................................................................3785 Air Conditioner Troubleshooting Chart 2...........................................................................................................3786 KomVision System..................................................................................................................................3789 Structure and Operation of KomVision System.......................................................................................................3790 Precautions for KomVision System..............................................................................................................3790 Layout Drawing of KomVision System............................................................................................................3791 Layout Drawing of KomVision Switches and Monitors (Applicable Machine: 30015 to 30157)....................................................3792 Layout Drawing of KomVision Switches and Monitors (Applicable Machine: 30158 and up)......................................................3792 System Diagram of KomVision System........................................................................................................3793 Function of KomVision System..............................................................................................................3793 Component Parts of KomVision System...........................................................................................................3795 KomVision Controller......................................................................................................................3795 KomVision Monitor.........................................................................................................................3804 KomVision Camera..........................................................................................................................3813 Examine and Adjust KomVision System...............................................................................................................3814 Set and Operate KomVision Monitor.............................................................................................................3814 Setting Default of KomVision System.......................................................................................................3814 Touch Panel Operation (Applicable Machine: 30015 to 30157)................................................................................3815 Touch Panel Operation (Applicable Machine: 30158 and up)..................................................................................3816 Operator Mode and Maintenance Mode of KomVision Monitor...................................................................................3816 How to Operate KomVision Maintenance Mode (Applicable Machine: 30015 to 30157)............................................................3817 How to Operate KomVision Maintenance Mode (Applicable Machine: 30158 and up)..............................................................3819 How to Operate Main Settings (Applicable Machine: 30015 to 30157).........................................................................3821 How to Operate Main Settings (Applicable Machine: 30158 and up)...........................................................................3824 How to Examine System Status (Applicable Machine: 30015 to 30157).........................................................................3831 How to Examine System Status (Applicable Machine: 30158 and up)...........................................................................3832 How to Examine Error Log (Applicable Machine: 30015 to 30157).............................................................................3833 How to Examine Error Log (Applicable Machine: 30158 and up)...............................................................................3834 How to Perform Check Disk (Applicable Machine: 30015 to 30157)............................................................................3835 How to Perform Check Disk (Applicable Machine: 30158 and up)..............................................................................3835 How to Initialize KomVision Controller Setting (Applicable Machine: 30015 to 30157).......................................................3836 How to Initialize KomVision Controller Setting (Applicable Machine: 30158 and up).........................................................3837 Camera Calibration............................................................................................................................3839 7 Camera Calibration..........................................................................................................................3840 Calibration Sheet.........................................................................................................................3840 How to Operate 7 Camera Calibration.......................................................................................................3851 1 Camera Calibration..........................................................................................................................3872 How to Do 1 Camera Calibration (Applicable Machine: 30015 to 30157).......................................................................3872 How to Do 1 Camera Calibration (Applicable Machine: 30158 and up).........................................................................3876 Troubleshooting for KomVision System..............................................................................................................3881 Related Information to Troubleshooting........................................................................................................3881 Preparation for Troubleshooting of Electrical System......................................................................................3881 Procedure for Troubleshooting (Applicable Machine: 30015 to 30157)........................................................................3886 Procedure for Troubleshooting (Applicable Machine: 30158 and up)..........................................................................3889 Symptom and Troubleshooting Numbers.......................................................................................................3893 Information Shown in Troubleshooting Table................................................................................................3894 Connector List and Layout (Applicable Machine: 30015 to 30157)............................................................................3896 Connector List and Layout (Applicable Machine: 30158 and up)..............................................................................3899 Failure Code Table............................................................................................................................3902 Failure Code [DBP0KM].....................................................................................................................3904 Failure Code [DBP0KT].....................................................................................................................3905 Failure Code [DBP0MC].....................................................................................................................3906 Failure Code [DBP0NR].....................................................................................................................3907 Failure Code [DBP5KP] (Applicable Machine: 30015 to 30157)................................................................................3908 Failure Code [DBP5KP] (Applicable Machine: 30158 and up)..................................................................................3911 Failure Code [DBPLKA].....................................................................................................................3914 Failure Code [DBPLKB].....................................................................................................................3917 Failure Code [DBPRKR] (Applicable Machine: 30015 to 30157)................................................................................3919 Failure Code [DBPRKR] (Applicable Machine: 30158 and up)..................................................................................3925 Failure Code [DPQ1LD].....................................................................................................................3931 Failure Code [DPQ4KB].....................................................................................................................3932 Failure Code [DR10KA].....................................................................................................................3933 Failure Code [DR20KA].....................................................................................................................3935 Failure Code [DR30KA].....................................................................................................................3937 Failure Code [DR40KA].....................................................................................................................3939 Failure Code [DR50KA].....................................................................................................................3941 Failure Code [DR60KA].....................................................................................................................3943 Failure Code [DR90KA].....................................................................................................................3945 Troubleshooting of Electrical System (E-Mode).................................................................................................3947 E-67 KomVision Monitor Does Not Come On or Backlight Flickers (Applicable Machine: 30015 to 30157)........................................3947 E-68 KomVision Monitor Does Not Come On or Backlight Flickers (Applicable Machine: 30158 and up)..........................................3951 E-69 KomVision Monitor Images are Not Shown Clearly (Applicable Machine: 30015 to 30157)..................................................3954 E-70 KomVision Monitor Images are Not Shown Clearly (Applicable Machine: 30158 and up)....................................................3961 E-71 KomVision Monitor Cannot be Touch (Applicable Machine: 30015 to 30157)...............................................................3967 E-72 KomVision Monitor Cannot be Touch (Applicable Machine: 30158 and up).................................................................3970 E-73 Night Lighting Lamp of KomVision Monitor is Abnormal (Applicable Machine: 30015 to 30157)............................................3972 E-74 Night Lighting Lamp of KomVision Monitor is Abnormal (Applicable Machine: 30158 and up)..............................................3975 E-75 Part of Camera Image is Not Shown on the KomVision Monitor (Applicable Machine: 30015 to 30157)......................................3978 E-76 Part of Camera Image is Not Shown on the KomVision Monitor (Applicable Machine: 30158 and up)........................................3980 E-77 Image on KomVision Monitor is Not Shown Correctly After Calibration..................................................................3982 90 Circuit Diagrams...................................................................................................................................3983 Table of Contents.................................................................................................................................3984 Hydraulic Circuit Diagram.........................................................................................................................3986 Symbols Used in Hydraulic Circuit Diagram.....................................................................................................3986 Hydraulic Circuit Diagram.....................................................................................................................3991 Hydraulic Circuit Diagram(1/2) (Loading Shovel Specification).................................................................................3993 Hydraulic Circuit Diagram(2/2) (Loading Shovel Specification).................................................................................3995 Electrical Circuit Diagram........................................................................................................................3997 Symbols Used in Electric Circuit Diagram......................................................................................................3997 Electrical Circuit Diagram (1/29).............................................................................................................4001 Electrical Circuit Diagram (2/29).............................................................................................................4003 Electrical Circuit Diagram (3/29).............................................................................................................4005 Electrical Circuit Diagram (4/29).............................................................................................................4007 Electrical Circuit Diagram (5/29).............................................................................................................4009 Electrical Circuit Diagram (6/29).............................................................................................................4011 Electrical Circuit Diagram (7/29).............................................................................................................4013 Electrical Circuit Diagram (8/29).............................................................................................................4015 Electrical Circuit Diagram (9/29).............................................................................................................4017 Electrical Circuit Diagram (10/29)............................................................................................................4019 Electrical Circuit Diagram (11/29)............................................................................................................4021 Electrical Circuit Diagram (12/29)............................................................................................................4023 Electrical Circuit Diagram (13/29)............................................................................................................4025 Electrical Circuit Diagram (14/29)............................................................................................................4027 Electrical Circuit Diagram (15/29)............................................................................................................4029 Electrical Circuit Diagram (16/29)............................................................................................................4031 Electrical Circuit Diagram (17/29)............................................................................................................4033 Electrical Circuit Diagram (18/29)............................................................................................................4035 Electrical Circuit Diagram (19/29)............................................................................................................4037 Electrical Circuit Diagram (20/29)............................................................................................................4039 Electrical Circuit Diagram (21/29) (Applicable Machine: 30015 to 30157).......................................................................4041 Electrical Circuit Diagram (21/29) (Applicable Machine: 30158 and up).........................................................................4043 Electrical Circuit Diagram (22/29)............................................................................................................4045 Electrical Circuit Diagram (23/29)............................................................................................................4047 Electrical Circuit Diagram (24/29)............................................................................................................4049 Electrical Circuit Diagram (25/29)............................................................................................................4051 Electrical Circuit Diagram (26/29)............................................................................................................4053 Electrical Circuit Diagram (27/29)............................................................................................................4055 Electrical Circuit Diagram (28/29)............................................................................................................4057 Electrical Circuit Diagram (29/29)............................................................................................................4059 Electrical Circuit Diagram (1/30) (Loading Shovel Specification)..............................................................................4061 Electrical Circuit Diagram (2/30) (Loading Shovel Specification)..............................................................................4063 Electrical Circuit Diagram (3/30) (Loading Shovel Specification)..............................................................................4065 Electrical Circuit Diagram (4/30) (Loading Shovel Specification)..............................................................................4067 Electrical Circuit Diagram (5/30) (Loading Shovel Specification)..............................................................................4069 Electrical Circuit Diagram (6/30) (Loading Shovel Specification)..............................................................................4071 Electrical Circuit Diagram (7/30) (Loading Shovel Specification)..............................................................................4073 Electrical Circuit Diagram (8/30) (Loading Shovel Specification)..............................................................................4075 Electrical Circuit Diagram (9/30) (Loading Shovel Specification)..............................................................................4077 Electrical Circuit Diagram (10/30) (Loading Shovel Specification).............................................................................4079 Electrical Circuit Diagram (11/30) (Loading Shovel Specification).............................................................................4081 Electrical Circuit Diagram (12/30) (Loading Shovel Specification).............................................................................4083 Electrical Circuit Diagram (13/30) (Loading Shovel Specification).............................................................................4085 Electrical Circuit Diagram (14/30) (Loading Shovel Specification).............................................................................4087 Electrical Circuit Diagram (15/30) (Loading Shovel Specification).............................................................................4089 Electrical Circuit Diagram (16/30) (Loading Shovel Specification).............................................................................4091 Electrical Circuit Diagram (17/30) (Loading Shovel Specification).............................................................................4093 Electrical Circuit Diagram (18/30) (Loading Shovel Specification).............................................................................4095 Electrical Circuit Diagram (19/30) (Loading Shovel Specification).............................................................................4097 Electrical Circuit Diagram (20/30) (Loading Shovel Specification).............................................................................4099 Electrical Circuit Diagram (21/30) (Loading Shovel Specification) (Applicable Machine: 30015 to 30157)........................................4101 Electrical Circuit Diagram (21/30) (Loading Shovel Specification) (Applicable Machine: 30158 and up)..........................................4103 Electrical Circuit Diagram (22/30) (Loading Shovel Specification).............................................................................4105 Electrical Circuit Diagram (23/30) (Loading Shovel Specification).............................................................................4107 Electrical Circuit Diagram (24/30) (Loading Shovel Specification).............................................................................4109 Electrical Circuit Diagram (25/30) (Loading Shovel Specification).............................................................................4111 Electrical Circuit Diagram (26/30) (Loading Shovel Specification).............................................................................4113 Electrical Circuit Diagram (27/30) (Loading Shovel Specification).............................................................................4115 Electrical Circuit Diagram (28/30) (Loading Shovel Specification).............................................................................4117 Electrical Circuit Diagram (29/30) (Loading Shovel Specification).............................................................................4119 Electrical Circuit Diagram (30/30) (Loading Shovel Specification).............................................................................4121 Index..................................................................................................................................................4123
DESCRIPTION:
KOMATSU PC2000-11 E0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06889-06 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 31/12/24
