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KOMATSU PC2000-8 HYDRAULIC EXCAVATOR SHOP MANUAL(SEN01607-19)-PDF Download
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- KOMATSU PC2000-8 HYDRAULIC EXCAVATOR SHOP MANUAL
- PUBLICATION NUMBER:SEN01607-19
- SERIAL NUMBERS 20001 and up
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Description
KOMATSU PC2000-8 HYDRAULIC EXCAVATOR SHOP MANUAL(SEN01607-19)
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KOMATSU PC2000-8 HYDRAULIC EXCAVATOR SHOP MANUAL(SEN01607-19)-PDF DOWNLOAD:
Description:
KOMATSU PC2000-8 HYDRAULIC EXCAVATOR SHOP MANUAL(SEN01607-19)
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume. This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume. This section explains the method of reproducing, repairing, and replacing parts.
Table of Contents:
KOMATSU PC2000-8 HYDRAULIC EXCAVATOR SHOP MANUAL(SEN01607-19)
COVER ............................................................................................................. 1 00 Index and foreword.............................................................................................. 0 Index.......................................................................................................... 3 Composition of shop manual................................................................................. 4 Table of contents.......................................................................................... 6 Foreword and general information............................................................................... 19 Safety notice.............................................................................................. 20 How to read the shop manual................................................................................ 25 Explanation of terms for maintenance standard.............................................................. 27 Handling of electric equipment and hydraulic component..................................................... 29 Handling of connectors newly used for engines.............................................................. 38 How to read electric wire code............................................................................. 41 Precautions when carrying out operation.................................................................... 44 Method of disassembling and connecting push-pull type coupler.............................................. 47 Standard tightening torque table........................................................................... 50 Conversion table........................................................................................... 54 01 Specification................................................................................................... 0 Specification and technical data............................................................................... 61 Specification drawings..................................................................................... 62 Specifications............................................................................................. 66 Weight table............................................................................................... 70 Table of fuel, coolant and lubricants...................................................................... 76 10 Structure, function and maintenance standard.................................................................... 0 Engine and cooling system...................................................................................... 79 Radiator and oil cooler.................................................................................... 80 PTO........................................................................................................ 82 PTO lubrication system..................................................................................... 84 Power train.................................................................................................... 87 Power train................................................................................................ 88 Swing machinery............................................................................................ 90 Swing circle............................................................................................... 92 Final drive................................................................................................ 94 Sprocket................................................................................................... 96 Undercarriage and frame........................................................................................ 99 Track frame................................................................................................ 100 Idler...................................................................................................... 102 Carrier roller............................................................................................. 104 Track roller............................................................................................... 105 Track shoe................................................................................................. 106 HIC system................................................................................................. 111 Hydraulic system, Part 1....................................................................................... 119 Hydraulic piping drawing................................................................................... 122 Hydraulic tank............................................................................................. 126 Oil cooler................................................................................................. 128 Line oil filter............................................................................................ 130 Pilot oil filter........................................................................................... 131 Return oil filter.......................................................................................... 132 Motor drain oil filter..................................................................................... 133 Pump drain filter.......................................................................................... 134 Accumulator................................................................................................ 135 Travel junction valve...................................................................................... 137 Solenoid valve............................................................................................. 140 Hydraulic cylinder......................................................................................... 148 Greasing system............................................................................................ 152 Center swivel joint........................................................................................ 162 Hydraulic ladder system.................................................................................... 163 Service center system...................................................................................... 168 Hydraulic system, Part 2....................................................................................... 175 Hydraulic system, Part 2................................................................................... 176 Control valve.......................................................................................... 176 Electronic OLSS system................................................................................. 204 Swing motor............................................................................................ 208 Cooling fan motor (For radiator and oil cooler)........................................................ 216 Cooling fan pump....................................................................................... 222 Hydraulic system, Part 3....................................................................................... 237 Travel motor............................................................................................... 238 Hydraulic pump............................................................................................. 250 PPC valve.................................................................................................. 270 Variable back pressure valve............................................................................... 282 Suction selector valve..................................................................................... 286 PPC cut-off valve.......................................................................................... 290 Work equipment................................................................................................. 299 Work equipment............................................................................................. 300 Dimensions of work equipment............................................................................... 304 Cab and its attachments........................................................................................ 309 Cab and its attachments.................................................................................... 310 Air conditioner piping................................................................................. 310 Cab.................................................................................................... 311 Electrical system.............................................................................................. 315 Engine control............................................................................................. 316 Electrical control system.................................................................................. 327 Monitor system............................................................................................. 369 Sensor..................................................................................................... 397 ORBCOMM terminal........................................................................................... 409 20 Standard value table............................................................................................ 0 Standard service value table................................................................................... 411 Standard service value table for engine.................................................................... 412 Standard service value table for chassis (Backhoe specification)........................................... 413 Standard service value table for chassis (Loading shovel specification).................................... 424 30 Testing and adjusting........................................................................................... 0 Testing and adjusting, Part 1.................................................................................. 437 Tools for testing, adjusting, and troubleshooting.......................................................... 439 Measuring engine speed..................................................................................... 442 Testing air boost pressure................................................................................. 443 Testing exhaust temperature................................................................................ 444 Testing exhaust color...................................................................................... 445 Adjusting valve clearance.................................................................................. 447 Testing compression pressure............................................................................... 449 Testing blow-by pressure................................................................................... 451 Testing engine oil pressure................................................................................ 452 Handling fuel system parts................................................................................. 453 Releasing residual pressure in fuel system................................................................. 453 Testing fuel pressure...................................................................................... 454 Reduced cylinder mode operation............................................................................ 455 No-injection cranking...................................................................................... 455 Testing leakage from pressure limiter and return rate from injector........................................ 456 Bleeding air from fuel circuit............................................................................. 459 Bleeding air from fuel circuit (lowgrade fuel specification)............................................... 463 Testing fuel system for leakage............................................................................ 465 Testing and adjusting alternator belt tension.............................................................. 466 Testing and adjusting air conditioner compressor belt tension.............................................. 467 Handling controller high-voltage circuit................................................................... 468 Testing and adjusting, Part 2.................................................................................. 471 Testing swing circle bearing clearance..................................................................... 473 Remaining pressure relief from HIC circuit................................................................. 474 Gas filling in HIC circuit accumulator..................................................................... 475 Bleeding air from HIC circuit and supplying oil to it...................................................... 478 Testing and adjusting track shoe tension................................................................... 482 Testing and adjusting work equipment, swing and travel circuit oil pressures............................... 486 Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve)....... 490 Testing and adjusting main pump control signal............................................................. 492 Measuring fan speed........................................................................................ 495 Measuring fan pump EPC solenoid current.................................................................... 496 Measuring fan pump EPC solenoid valve output pressure...................................................... 497 Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure.............. 499 Measuring PPC valve output pressure........................................................................ 500 Measuring solenoid valve outlet pressure................................................................... 504 Adjusting work equipment and swing PPC valve............................................................... 506 Testing and adjusting travel deviation..................................................................... 507 Testing work equipment hydraulic drift cause portion....................................................... 509 Testing oil leakage........................................................................................ 510 Remaining pressure relief from hydraulic circuit........................................................... 513 Air bleeding from each component........................................................................... 514 Testing and adjusting auto grease system................................................................... 520 Adjusting mirrors.......................................................................................... 523 Testing and adjusting clearance of hydraulic ladder proximity switch....................................... 525 Testing and adjusting position of hydraulic ladder position sensor plate................................... 527 Testing and adjusting clearance to service arm proximity switch............................................ 528 Testing and adjusting, Part 3.................................................................................. 531 Special functions of machine monitor....................................................................... 532 Handling controller voltage circuit........................................................................ 587 Testing and adjusting, Part 4.................................................................................. 589 VHMS controller initial setting procedure.................................................................. 590 Precautions for replacing VHMS controller.................................................................. 609 Preparation work for troubleshooting of electrical system.................................................. 615 Pm-clinic service.......................................................................................... 617 Measurement procedure...................................................................................... 618 40 Troubleshooting................................................................................................. 0 Failure code table and fuse locations.......................................................................... 637 Failure code table......................................................................................... 638 Before carrying out troubleshooting of electrical system................................................... 645 General information on troubleshooting......................................................................... 653 Points to remember when troubleshooting.................................................................... 654 Sequence of events in troubleshooting...................................................................... 655 Checks before troubleshooting.............................................................................. 656 Classification and procedures of troubleshooting........................................................... 657 Connection table for connector pin numbers................................................................. 661 T- branch box and T- branch adapter table.................................................................. 697 Troubleshooting by failure code, Part 1........................................................................ 701 Failure code [0410KA] Fuel LV. Sensor Failure.............................................................. 704 Failure code [0410KB] Fuel LV. Sensor Failure.............................................................. 706 Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51).......... 708 Failure code [8800ZG] Auto grease abnormally............................................................... 709 Failure code [7@HAZL] VR1/P1F Relief Press Abnormality..................................................... 710 Failure code [7@HBZL] VL1/P1R Relief Press Abnormality..................................................... 711 Failure code [7@HCZL] VR2/P2F Relief Press Abnormality..................................................... 712 Failure code [7@HDZL] VL2/P2R Relief Press Abnormality..................................................... 714 Failure code [AA10NX] Aircleaner Clogging.................................................................. 716 Failure code [AB00KE] Charge Voltage Low................................................................... 718 Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11)........... 720 Failure code [B@BAZG] Eng. Oil Press. Low.................................................................. 722 Failure code [B@BAZK] Eng. Oil Level Low................................................................... 724 Failure code [B@BCNS] Eng. Water Overheat.................................................................. 726 Failure code [B@BCZK] Eng. Water Lvl Low................................................................... 728 Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61)....................... 730 Failure code [B@HANS] Hydr. Oil Overheat................................................................... 732 Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMSLED display from n5 to 52)................. 734 Failure code [CA111] ECM Critical Internal Failure......................................................... 736 Failure code [CB111] ECM Critical Internal Failure......................................................... 738 Failure code [CA115] Eng. Ne and Bkup Speed Sens Error..................................................... 740 Failure code [CB115] Eng. Ne and Bkup Speed Sens Error..................................................... 741 Failure code [CA122] Chg Air Press Sensor High Error....................................................... 742 Failure code [CA123] Chg Air Press Sensor Low Error........................................................ 744 Failure code [CA131] Throttle Sensor High Error............................................................ 746 Failure code [CA132] Throttle Sensor Low Error............................................................. 748 Failure code [CA135] Eng Oil Press Sensor High Error....................................................... 750 Failure code [CA141] Eng Oil Press Sensor Low Error........................................................ 752 Failure code [CA144] Coolant Temp Sens High Error.......................................................... 754 Failure code [CA145] Coolant Temp Sens Low Error........................................................... 756 Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 758 Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 760 Failure code [CA187] Sens Supply 2 Volt Low Error.......................................................... 762 Failure code [CB187] Sens Supply 2 Volt Low Error.......................................................... 762 Failure code [CA212] Eng Oil Temp Sensor High Error........................................................ 764 Failure code [CA213] Eng Oil Temp Sensor Low Error......................................................... 766 Troubleshooting by failure code, Part 2........................................................................ 769 Failure code [CA221] Ambient Press Sens High Error......................................................... 772 Failure code [CA222] Ambient Press Sens Low Error.......................................................... 774 Failure code [CA227] Sens Supply 2 Volt High Error......................................................... 776 Failure code [CB227] Sens Supply 2 Volt High Error......................................................... 778 Failure code [CA234] Eng Over Speed........................................................................ 780 Failure code [CA238] Ne Speed Sens Supply Volt Error....................................................... 782 Failure code [CB238] Ne Speed Sens Supply Volt Error....................................................... 784 Failure code [CA263] Fuel Temp Sensor High Error........................................................... 786 Failure code [CB263] Fuel Temp Sensor High Error........................................................... 788 Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 789 Failure code [CB265] Fuel Temp Sensor Low Error............................................................ 789 Failure code [CA271] IMV/PCV1 Short Error.................................................................. 790 Failure code [CB271] IMV/PCV1 Short Error.................................................................. 792 Failure code [CA272] IMV/PCV1 Open Error................................................................... 794 Failure code [CB272] IMV/PCV1 Open Error................................................................... 796 Failure code [CA273] PCV2 Short Error...................................................................... 798 Failure code [CB273] PCV2 Short Error...................................................................... 800 Failure code [CA274] PCV2 Open Error....................................................................... 802 Failure code [CB274] PCV2 Open Error....................................................................... 804 Failure code [CA322] Inj #1(L/B#1) Open/Short Error........................................................ 806 Failure code [CA323] Inj #5(L/B#5) Open/Short Error........................................................ 808 Failure code [CA324] Inj #3(L/B#3) Open/Short Error........................................................ 810 Failure code [CA325] Inj #6(L/B#6) Open/Short Error........................................................ 812 Failure code [CA331] Inj #2(L/B#2) Open/Short Error........................................................ 814 Failure code [CA332] Inj #4(L/B#4) Open/Short Error........................................................ 816 Failure code [CA342] Calibration Code Incompatibility...................................................... 818 Failure code [CB342] Calibration Code Incompatibility...................................................... 818 Failure code [CA351] Injectors Drive Circuit Error......................................................... 820 Failure code [CB351] Injectors Drive Circuit Error......................................................... 822 Failure code [CA352] Sens Supply 1 Volt Low Error.......................................................... 824 Failure code [CB352] Sens Supply 1 Volt Low Error.......................................................... 824 Failure code [CA386] Sens Supply 1 Volt High Error......................................................... 826 Failure code [CB386] Sens Supply 1 Volt High Error......................................................... 828 Failure code [CA441] Battery Voltage Low Error............................................................. 830 Failure code [CB441] Battery Voltage Low Error............................................................. 830 Failure code [CA442] Battery Voltage High Error............................................................ 831 Failure code [CB442] Battery Voltage High Error............................................................ 831 Failure code [CA449] Rail Press Very High Error............................................................ 832 Failure code [CB449] Rail Press Very High Error............................................................ 832 Troubleshooting by failure code, Part 3........................................................................ 835 Failure code [CA451] Rail Press Sensor High Error.......................................................... 838 Failure code [CB451] Rail Press Sensor High Error.......................................................... 840 Failure code [CA452] Rail Press Sensor Low Error........................................................... 842 Failure code [CB452] Rail Press Sensor Low Error........................................................... 842 Failure code [CA553] Rail Press High Error................................................................. 843 Failure code [CB553] Rail Press High Error................................................................. 844 Failure code [CA554] Rail Press Sensor In Range Error...................................................... 845 Failure code [CB554] Rail Press Sensor In Range Error...................................................... 845 Failure code [CA559] Rail Press Low Error.................................................................. 846 Failure code [CB559] Rail Press Low Error.................................................................. 850 Failure code [CA689] Eng Ne Speed Sensor Error............................................................. 854 Failure code [CB689] Eng Ne Speed Sensor Error............................................................. 856 Failure code [CA691] Intake Air Temp Sens High Error....................................................... 858 Failure code [CA692] Intake Air Temp Sens Low Error........................................................ 860 Failure code [CA731] Eng Bkup Speed Sens Phase Error....................................................... 861 Failure code [CB731] Eng Bkup Speed Sens Phase Error....................................................... 861 Failure code [CA757] All Persistent Data Lost Error........................................................ 862 Failure code [CB757] All Persistent Data Lost Error........................................................ 862 Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 864 Failure code [CB778] Eng Bkup Speed Sensor Error........................................................... 866 Failure code [CA781] CEN Communication Error............................................................... 868 Failure code [CB781] CEN Communication Error............................................................... 870 Failure code [CA1257] Harness Key Error.................................................................... 872 Failure code [CB1257] Harness Key Error.................................................................... 873 Failure code [CB1548] Inj #7(R/B#1) Open/Short Error....................................................... 874 Failure code [CB1549] Inj #8(R/B#2) Open/Short Error....................................................... 876 Failure code [CB1551] Inj #10(R/B#4) Open/Short Error...................................................... 878 Failure code [CB1552] Inj #11(R/B#5) Open/Short Error...................................................... 880 Failure code [CB1553] Inj #12(R/B#6) Open/Short Error...................................................... 882 Failure code [CB1622] Inj #9(R/B#3) Open/Short Error....................................................... 884 Failure code [CA1633] KOMNET Data link Time out Error...................................................... 886 Failure code [CA2185] Throt Sens Sup Volt High Error....................................................... 888 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................ 890 Failure code [CA2249] Rail Press Very Low Error............................................................ 891 Failure code [CB2249] Rail Press Very Low Error............................................................ 891 Failure code [CA2555] Grid Heater Relay Volt Low Error..................................................... 892 Failure code [CA2556] Grid Heater Relay Volt High Error.................................................... 894 Troubleshooting by failure code, Part 4........................................................................ 897 Failure code [D110KB] Battery Relay Drive S/C.............................................................. 900 Failure code [D163KB] Flash Light Relay S/C................................................................ 902 Failure code [D195KA] Step Light Relay Disc................................................................ 904 Failure code [D195KY] Step Light Relay S/C................................................................. 906 Failure code [D1E9KB] Wiper Drive Relay 1 S/C.............................................................. 908 Failure code [D1EAKB] Wiper Drive Relay 2 S/C.............................................................. 910 Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit................................................ 912 Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit................................................ 914 Failure code [DA22KK] Pump 1 Solenoid Power Low Error...................................................... 916 Failure code [dA22KK] Pump 2 Solenoid Power Low Error...................................................... 918 Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error..................................................... 920 Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error..................................................... 922 Failure code [DA26KP] 5V Sensor 2 Power Abnormality........................................................ 924 Failure code [DA29KQ] Pump 1 Model Select Abnormality...................................................... 926 Failure code [dA29KQ] Pump 2 Model Select Abnormality...................................................... 928 Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected)..................................................... 930 Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected)..................................................... 932 Failure code [DAFRMC] CAN Discon (Monitor Detected)........................................................ 934 Failure code [DA2TMC] Pump Comm. ECM Child Abnormality..................................................... 936 Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01).............. 938 Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11)................ 940 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMSLED display from n9 to 04)................ 942 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02).............. 944 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)........................ 946 Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01)........ 948 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C........................................................... 950 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01)................. 952 Troubleshooting by failure code, Part 5........................................................................ 955 Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12)....... 958 Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22)....... 960 Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11)....... 962 Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21)....... 964 Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24)....... 966 Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)....... 968 Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23)....... 970 Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26)....... 972 Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality............................................. 974 Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality............................................. 976 Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality............................................. 978 Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality............................................. 980 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32)............ 982 Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31)............ 984 Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53).... 986 Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality................................................... 988 Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality................................................... 990 Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality................................................... 992 Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality................................................... 994 Failure code [DHPSKX] Auto Grease Press Sensor Abnormality................................................. 996 Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit................................................. 998 Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit.................................................1000 Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality.................................................1002 Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality.............................................1004 Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality..............................................1006 Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality..............................................1008 Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality.............................................1010 Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality..............................................1012 Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality................................................1014 Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality.............................................1016 Troubleshooting by failure code, Part 6........................................................................1019 Failure code [DUM3KB] Auto Grease Caution LED Short Circuit................................................1021 Failure code [DUM4KB] FAN Reverse LED Short Circuit........................................................1022 Failure code [DV20KB] Travel Alarm S/C.....................................................................1023 Failure code [DW41KA] Swing Priority Sol Open Circuit......................................................1025 Failure code [DW41KB] Swing Priority Sol Short Circuit.....................................................1027 Failure code [DW45KA] Swing Brake Sol. Disc................................................................1029 Failure code [DW45KB] Swing Brake Sol. S/C.................................................................1032 Failure code [DW91KA] Straight-Travel Sol. Disc............................................................1034 Failure code [DW91KB] Straight-Travel Sol. S/C.............................................................1036 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc......................................................1038 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C.......................................................1039 Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit.............................................1040 Failure code [DW7BKB] Fan Motor (RAD) Reverse Sol. S/C.....................................................1042 Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit..............................................1044 Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit.............................................1046 Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit................................................1048 Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit...............................................1050 Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit................................................1052 Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit...............................................1054 Failure code [DWA5KA] Auto Grease Sol Open Circuit.........................................................1056 Failure code [DWA5KB] Auto Grease Sol Short Circuit........................................................1058 Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit.................................................1059 Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit................................................1061 Failure code [DWK0KA] 2-stage Relief Sol. Disc.............................................................1063 Failure code [DWK0KB] 2-stage Relief Sol. S/C..............................................................1065 Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit...............................................1066 Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit..............................................1067 Troubleshooting by failure code, Part 7........................................................................1069 Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit...................................................1071 Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit..................................................1072 Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit...................................................1073 Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit..................................................1074 Failure code [DXAAKA] P1F EPC Sol Disc.....................................................................1076 Failure code [DXAAKB] P1F EPC Sol S/C......................................................................1078 Failure code [DXABKA] P1R Pump EPC Sol. Disc...............................................................1080 Failure code [DXABKB] P1R Pump EPC Sol. S/C................................................................1082 Failure code [DXACKA] P2F Pump EPC Sol. Disc...............................................................1084 Failure code [DXACKB] P2F Pump EPC Sol. S/C................................................................1086 Failure code [DXADKA] P2R Pump EPC Sol. Disc...............................................................1088 Failure code [DXADKB] P2R Pump EPC Sol. S/C................................................................1090 Failure code [DY2CKB] Washer Drive S/C.....................................................................1092 Failure code [DY20MA] Low Wiper Working Abnormality........................................................1094 Failure code [DY2FMA] Upper Wiper Working Abnormality......................................................1097 Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)...................1100 Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62).........1102 Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72).........1104 Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61)..............1106 Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71)..............1108 Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82).........1110 Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92).........1112 Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81)..............1114 Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91)..............1116 Failure code [LA10ZL] RAD system fan pump relief pressure high error.......................................1118 Failure code [LA20ZL] O/C system pump relief pressure high error...........................................1120 Troubleshooting of electrical system (E-mode)..................................................................1123 Before carrying out troubleshooting of electrical system...................................................1125 Contents of troubleshooting table..........................................................................1132 E-1 When starting switch is turned ON, machine monitor displays nothing....................................1134 E-2 When starting switch turned ON (before starting engine), basic check item lights up....................1136 E-3 Engine does not start (Engine does not turn)...........................................................1138 E-4 Auto-decelerator does not operate......................................................................1142 E-5 Automatic warm-up system does not operate..............................................................1143 E-6 Preheater does not work................................................................................1144 E-7 Whole work equipment, swing operation and machine travel operation are disabled........................1146 E-8 Machine push-up function does not work.................................................................1148 E-9 Boom shockless function cannot be released.............................................................1150 E-10 Machine monitor does not display some items...........................................................1152 E-11 Contents of display by machine monitor are different from applicable machine..........................1153 E-12 Fuel level monitor lights up in red while engine is running...........................................1154 E-13 Hydraulic oil temperature gauge does not indicate normally............................................1155 E-14 Fuel level gauge does not indicate normally...........................................................1156 E-15 Swing lock monitor does not indicate normally.........................................................1158 E-16 Machine monitor display anything even when operated on monitor switch section.........................1160 E-17 Wiper does not work...................................................................................1161 E-18 Monitoring function does not display "Travel" normally................................................1168 E-19 Travel alarm does not sound...........................................................................1170 E-20 All of room lamp, headlamp and working lamp do not light up...........................................1171 E-21 Air conditioner does not work.........................................................................1176 E-22 Step light does not light up or goes off..............................................................1178 Troubleshooting of hydraulic and mechanical system (H-mode)....................................................1183 Before troubleshooting for hydraulic and mechanical systems................................................1185 Table of failure modes and causes..........................................................................1190 Information in troubleshooting table.......................................................................1192 H-1 Speed or power of whole work equipment, travel, and swing is low.......................................1193 H-2 Engine speed lowers remarkably or engine stalls........................................................1195 H-3 Work equipment, swing, and travel mechanism do not move................................................1196 H-4 Abnormal noise comes from around hydraulic pump........................................................1198 H-5 Speed or power of boom is low..........................................................................1199 H-6 Speed or power of arm is low...........................................................................1201 H-7 Speed or power of bucket is low........................................................................1202 H-8 Boom does not move.....................................................................................1203 H-9 Arm does not move......................................................................................1203 H-10 Bucket does not move..................................................................................1203 H-11 Hydraulic drift of work equipment is large............................................................1204 H-12 Time lag of work equipment is large...................................................................1205 H-13 Heavy lift function does not work or is not reset.....................................................1206 H-14 Machine push-up function does not work or is not reset................................................1206 H-15 Boom shockless function does not work or is not reset.................................................1206 H-16 Machine gradually deviates during traveling...........................................................1208 H-17 Machine deviates excessively when started to travel...................................................1211 H-18 Machine deviates excessively during multiple operations...............................................1212 H-19 Traveling speed or power is low.......................................................................1212 H-20 Travel system does not move (only one side)...........................................................1213 H-21 Upper structure does not swing........................................................................1214 H-22 Swing speed or acceleration is low....................................................................1216 H-23 In compound operation of work equipment, swing speed or acceleration is low...........................1218 H-24 Upper structure overruns remarkably when it stops swinging............................................1219 H-25 Large shock is made when upper structure stops swinging...............................................1220 H-26 Large abnormal sound comes from when upper structure stops swinging...................................1221 H-27 Hydraulic drift of work equipment is large in swing operation.........................................1222 H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating).......................1223 H-29 Bottom dump speed or power is lower (Loading shovel specification)....................................1224 H-30 Bottom dump cylinder does not move (Loading shovel specification).....................................1225 Troubleshooting of mechanical system (S-mode)..................................................................1227 Method of using troubleshooting charts.....................................................................1229 S-1 Starting performance is poor...........................................................................1232 S-2 Engine does not start..................................................................................1233 S-3 Engine does not pick up smoothly.......................................................................1236 S-4 Engine stops during operations.........................................................................1237 S-5 Engine does not rotate smoothly........................................................................1238 S-6 Engine lacks output (or lacks power)...................................................................1240 S-7 Exhaust smoke is black (incomplete combustion).........................................................1242 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................1243 S-9 Oil becomes contaminated quickly.......................................................................1244 S-10 Fuel consumption is excessive.........................................................................1245 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................1246 S-12 Oil pressure drops....................................................................................1247 S-13 Oil level rises (Entry of coolant or fuel)............................................................1248 S-14 Coolant temperature becomes too high (overheating)....................................................1249 S-15 Abnormal noise is made................................................................................1250 S-16 Vibration is excessive................................................................................1251 50 Disassembly and assembly........................................................................................ 0 General information on disassembly and assembly................................................................1253 How to read this manual....................................................................................1254 Coating materials list.....................................................................................1256 Special tool list..........................................................................................1259 Sketches of special tools..................................................................................1263 Engine and cooling system......................................................................................1267 Removal and installation of power container assembly.......................................................1268 Removal and installation of engine, PTO and hydraulic pump assembly........................................1273 Removal and installation of radiator assembly..............................................................1285 Removal and installation of aftercooler assembly...........................................................1286 Removal and installation of hydraulic oil cooler assembly..................................................1288 Removal and installation of fuel cooler assembly...........................................................1289 Removal and installation of cooling assembly...............................................................1290 Removal and installation of fan motor assembly.............................................................1294 Removal and installation of fuel tank assembly.............................................................1295 Engine.........................................................................................................1299 Removal and installation of fuel supply pump assembly......................................................1300 Removal and installation of cylinder head assembly.........................................................1304 Removal and installation of fuel injector..................................................................1318 Removal and installation of engine front oil seal..........................................................1329 Removal and installation of engine rear oil seal...........................................................1332 Power train....................................................................................................1337 Removal and installation of PTO assembly...................................................................1338 Disassembly and assembly of PTO assembly...................................................................1339 Removal and installation of swing motor and swing machinery assembly.......................................1343 Disassembly and assembly of swing machinery assembly.......................................................1345 Removal and installation of swing circle assembly..........................................................1355 Removal and installation of final drive assembly...........................................................1356 Disassembly and assembly of final drive assembly...........................................................1358 Undercarriage and frame........................................................................................1371 Removal and installation of track shoe assembly............................................................1372 Removal and installation of idler assembly.................................................................1374 Disassembly and assembly of idler assembly.................................................................1375 Disassembly and assembly of idler adjust cylinder assembly.................................................1377 Removal and installation of idler cushion cylinder assembly................................................1378 Disassembly and assembly of idler cushion cylinder assembly................................................1379 Removal and installation of track roller assembly..........................................................1380 Disassembly and assembly of track roller assembly..........................................................1381 Removal and installation of carrier roller assembly........................................................1383 Disassembly and assembly of carrier roller assembly........................................................1384 Removal and installation of revolving frame assembly.......................................................1388 Removal and installation of counterweight assembly.........................................................1391 Removal and installation of hydraulic ladder...............................................................1392 Hydraulic system...............................................................................................1395 Removal and installation of hydraulic tank assembly........................................................1396 Removal and installation of hydraulic pump assembly........................................................1399 Removal and installation of hydraulic pump input shaft oil seal............................................1404 Removal and installation of control valve assembly.........................................................1405 Disassembly and assembly of control valve assembly.........................................................1412 Removal and installation of center swivel joint assembly...................................................1416 Disassembly and assembly of center swivel joint assembly...................................................1417 Removal and installation of swing motor assembly...........................................................1418 Removal and installation of travel motor assembly..........................................................1419 Disassembly and assembly of work equipment PPC valve assembly..............................................1420 Disassembly and assembly of travel PPC valve assembly......................................................1422 Disassembly and assembly of hydraulic cylinder assembly (Backhoe specification)............................1425 Disassembly and assembly of hydraulic cylinder assembly (Loading shovel specification).....................1432 Work equipment.................................................................................................1439 Removal and installation of bucket cylinder assembly (Backhoe specification)...............................1440 Removal and installation of bucket cylinder assembly (Loading shovel specification)........................1442 Removal and installation of bucket assembly (Backhoe specification)........................................1444 Removal and installation of bucket assembly (Loading shovel specification).................................1446 Removal and installation of arm cylinder (Backhoe specification)...........................................1448 Removal and installation of arm cylinder (Loading shovel specification)....................................1450 Removal and installation of arm assembly (Backhoe specification)...........................................1451 Removal and installation of arm assembly (Loading shovel specification)....................................1453 Removal and installation of boom cylinder assembly (Backhoe specification).................................1454 Removal and installation of boom cylinder assembly (Loading shovel specification)..........................1456 Removal and installation of boom assembly (Backhoe specification)..........................................1458 Removal and installation of boom assembly (Loading shovel specification)...................................1460 Removal and installation of bottom dump cylinder assembly (Loading shovel specification)...................1462 Cab and its attachments........................................................................................1465 Removal and installation of operator cab assembly..........................................................1466 Removal and installation of operator cab glass (adhesion glass)............................................1469 Removal and installation of operator cab (assembly-type)...................................................1476 Removal and installation of cab base assembly..............................................................1477 Removal and installation of service center.................................................................1479 Electrical system..............................................................................................1483 Removal and installation of air conditioner unit assembly..................................................1484 Removal and installation of monitor assembly...............................................................1488 Removal and installation of engine controller assembly.....................................................1489 Removal and installation of pump controller assembly.......................................................1490 Removal and installation of VHMS controller assembly.......................................................1491 Removal and installation of Orbcomm terminal assembly for VHMS.............................................1491 90 Diagrams and drawings........................................................................................... 0 Hydraulic diagrams and drawings................................................................................1493 Hydraulic circuit diagram (Backhoe specification) Serial No.: 20001 – 20197................................1495 Hydraulic circuit diagram (Backhoe specification) Serial No.: 20198 and up.................................1496 Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20001 – 20197.........................1497 Hydraulic circuit diagram (Loading shovel specification) Serial No.: 20198 and up..........................1498 Electrical diagrams and drawings...............................................................................1501 Electrical circuit diagram (1/14)..........................................................................1503 Electrical circuit diagram (2/14)..........................................................................1504 Electrical circuit diagram (3/14)..........................................................................1505 Electrical circuit diagram (4/14)..........................................................................1506 Electrical circuit diagram (5/14)..........................................................................1507 Electrical circuit diagram (6/14)..........................................................................1508 Electrical circuit diagram (7/14)..........................................................................1509 Electrical circuit diagram (8/14)..........................................................................1510 Electrical circuit diagram (9/14)..........................................................................1511 Electrical circuit diagram (10/14).........................................................................1512 Electrical circuit diagram (11/14).........................................................................1513 Electrical circuit diagram (12/14).........................................................................1514 Electrical circuit diagram (13/14).........................................................................1515 Electrical circuit diagram (14/14).........................................................................1516 Connector list and stereogram..............................................................................1517
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