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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C0 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C0 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C0 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C0 – PDF DOWNLOAD
Language : English
Pages : 2500
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C0 – PDF DOWNLOAD
COVER ................................................................................................................................... 1 00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 16 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 21 HOW TO READ THE SHOP MANUAL..................................................................................................... 21 SAFETY NOTICE FOR OPERATION..................................................................................................... 23 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 31 ACTIONS IF FIRE OCCURS.......................................................................................................... 32 PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS................................................................................. 33 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 34 PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS............................................................................. 37 PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT................................................................................ 44 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 46 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 47 PRACTICAL USE OF KOMTRAX........................................................................................................ 48 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 49 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 49 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 50 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 51 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 53 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 57 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 60 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 61 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 63 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 64 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 68 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 71 CONVERSION TABLE................................................................................................................ 78 01 SPECIFICATION........................................................................................................................ 83 CONTENTS............................................................................................................................ 84 ABBREVIATION LIST................................................................................................................... 85 SPECIFICATION....................................................................................................................... 90 SPECIFICATION DRAWING........................................................................................................... 90 SPECIFICATION DRAWING: PC210-10M0........................................................................................... 90 SPECIFICATION DRAWING: PC210LC-10M0......................................................................................... 91 WORKING RANGE DRAWINGS.......................................................................................................... 93 WORKING RANGE DRAWINGS: PC210-10M0.......................................................................................... 93 WORKING RANGE DRAWINGS: PC210LC-10M0........................................................................................ 94 SPECIFICATION................................................................................................................... 96 SPECIFICATION: PC210-10M0................................................................................................... 96 SPECIFICATIONS: PC210LC-10M0................................................................................................ 98 WEIGHT TABLE.................................................................................................................... 102 WEIGHT TABLE: PC210-10M0.................................................................................................... 102 WEIGHT TABLE: PC210LC-10M0.................................................................................................. 103 FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE......................................................................... 105 10 STRUCTURE AND FUNCTION............................................................................................................... 107 CONTENTS............................................................................................................................ 108 ABBREVIATION LIST................................................................................................................... 111 BOOT-UP SYSTEM...................................................................................................................... 116 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 116 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 117 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 117 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 117 OPERATION OF SYSTEM OPERATING LAMP.......................................................................................... 117 BATTERY DISCONNECT SWITCH....................................................................................................... 118 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 118 OPERATION OF BATTERY DISCONNECT SWITCH...................................................................................... 118 ENGINE SYSTEM....................................................................................................................... 119 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 119 ENGINE CONTROL SYSTEM........................................................................................................... 120 ENGINE CONTROL SYSTEM DRAWING............................................................................................... 120 OPERATION OF ENGINE CONTROL SYSTEM.......................................................................................... 120 AUTO-DECELERATION SYSTEM........................................................................................................ 122 AUTO-DECELERATION SYSTEM DRAWING............................................................................................ 122 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 122 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 123 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 124 ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING..................................................................................... 124 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 125 OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................ 125 OVERHEAT PREVENTION SYSTEM...................................................................................................... 126 OVERHEAT PREVENTION SYSTEM DRAWING.......................................................................................... 126 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 127 OPERATION OF OVERHEAT PREVENTION SYSTEM..................................................................................... 127 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 129 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 129 COOLING SYSTEM...................................................................................................................... 130 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 130 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 131 CONTROL SYSTEM...................................................................................................................... 132 LAYOUT DRAWING OF CONTROL SYSTEM PARTS.......................................................................................... 132 MACHINE MONITOR SYSTEM.......................................................................................................... 134 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 134 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 134 KOMTRAX SYSTEM.................................................................................................................. 136 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 136 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 136 CONTROL SYSTEM.................................................................................................................. 137 MACHINE MONITOR............................................................................................................. 137 KOMTRAX TERMINAL............................................................................................................ 148 PUMP CONTROLLER............................................................................................................. 151 RESISTOR FOR PC-EPC VALVE................................................................................................... 155 CAN TERMINATING RESISTOR.................................................................................................... 155 ENGINE CONTROLLER........................................................................................................... 156 FUEL CONTROL DIAL........................................................................................................... 160 HYDRAULIC SYSTEM.................................................................................................................... 161 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 161 CLSS............................................................................................................................ 164 CLSS SYSTEM DIAGRAM......................................................................................................... 164 FUNCTION OF CLSS............................................................................................................ 165 PRESSURE COMPENSATION CONTROL............................................................................................... 182 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 183 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 183 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 184 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 188 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 188 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 189 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 191 HYDRAULIC TANK.............................................................................................................. 191 MAIN PUMP................................................................................................................... 193 CONTROL VALVE............................................................................................................... 213 WORK EQUIPMENT SYSTEM............................................................................................................... 259 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 259 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 263 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 263 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 264 PPC LOCK SYSTEM................................................................................................................. 265 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 265 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 266 ATTACHMENT OIL FLOW ADJUSTER SYSTEM............................................................................................. 267 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................. 267 FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM............................................................................. 268 WORK EQUIPMENT SYSTEM........................................................................................................... 269 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 269 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 273 2ND-LINE ATTACHMENT PPC VALVE............................................................................................... 278 SOLENOID VALVE.............................................................................................................. 282 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)....................................................................... 284 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)........................................................................ 286 PILOT CIRCUIT ACCUMULATOR................................................................................................... 289 ATTACHMENT CIRCUIT ACCUMULATOR.............................................................................................. 289 SWING SYSTEM........................................................................................................................ 292 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 292 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 294 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 294 SWING SYSTEM.................................................................................................................... 298 SWING MOTOR................................................................................................................. 298 SWING MACHINERY............................................................................................................. 307 SWING CIRCLE................................................................................................................ 309 TRAVEL SYSTEM....................................................................................................................... 310 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 310 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 312 FUNCTION OF TRAVEL CONTROL SYSTEM............................................................................................... 313 TRAVEL SYSTEM................................................................................................................... 314 TRAVEL MOTOR................................................................................................................ 314 FINAL DRIVE................................................................................................................. 325 TRAVEL PPC VALVE............................................................................................................ 326 CENTER SWIVEL JOINT......................................................................................................... 331 FUNCTION OF SWING CIRCLE............................................................................................................ 333 UNDERCARRIAGE AND FRAME............................................................................................................. 334 LAYOUT DRAWING OF UNDERCARRIAG.................................................................................................. 334 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 334 WORK EQUIPMENT...................................................................................................................... 336 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 336 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 337 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 337 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 338 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 338 CAB RELATED PARTS................................................................................................................... 339 ROPS CAB........................................................................................................................ 339 STRUCTURE OF ROPS CAB....................................................................................................... 339 FUNCTION OF ROPS CAB........................................................................................................ 339 CAB MOUNT....................................................................................................................... 340 STRUCTURE OF CAB MOUNT...................................................................................................... 340 FUNCTION OF CAB MOUNT....................................................................................................... 341 CAB TIPPING STOPPER............................................................................................................. 342 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 342 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 342 20 STANDARD VALUE TABLE................................................................................................................. 343 CONTENTS............................................................................................................................ 344 ABBREVIATION LIST................................................................................................................... 345 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 350 STANDARD VALUE TABLE FOR ENGINE: PC210-10M0..................................................................................... 350 STANDARD VALUE TABLE FOR MACHINE: PC210-10M0.................................................................................... 354 STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0................................................................................... 368 STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0.................................................................................. 372 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE........................................................................... 386 30 TESTING AND ADJUSTING................................................................................................................ 389 CONTENTS............................................................................................................................ 390 ABBREVIATION LIST................................................................................................................... 393 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 398 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 398 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 403 ENGINE AND COOLING SYSTEM........................................................................................................... 405 TEST ENGINE SPEED............................................................................................................... 405 TEST ENGINE HIGH IDLE SPEED................................................................................................. 405 Test engine low idle speed.................................................................................................. 405 TEST ENGINE SPEED AT 2 PUMPS RELIEF......................................................................................... 405 Test engine speed at 2 pumps relief and one-touch power maximizing.......................................................... 406 TEST ENGINE SPEED WITH AUTO-DECELERATION.................................................................................... 406 Test boost pressure............................................................................................................. 408 TEST BOOST PRESSURE ON MACHINE MONITOR...................................................................................... 408 TEST BOOST PRESSURE BY TESTING TOOL......................................................................................... 409 TEST EXHAUST GAS COLOR.......................................................................................................... 411 Test exhaust gas color by handy smoke checker............................................................................... 411 TEST EXHAUST GAS COLOR BY SMOKE METER....................................................................................... 412 Test and adjust valve clearance................................................................................................. 414 TEST VALVE CLEARANCE........................................................................................................ 414 Adjust valve clearance...................................................................................................... 415 TEST COMPRESSION PRESSURE....................................................................................................... 417 TEST COMPRESSION PRESSURE................................................................................................... 417 TEST BLOWBY PRESSURE............................................................................................................ 420 TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT))......................................... 420 Test blowby pressure (machine without blowby pressure sensor)............................................................... 421 TEST ENGINE OIL PRESSURE........................................................................................................ 423 TEST ENGINE OIL PRESSURE.................................................................................................... 423 Test fuel pressure.............................................................................................................. 425 TEST FUEL PRESSURE.......................................................................................................... 426 Test fuel discharged volume, return rate, and leakage........................................................................... 432 TEST FUEL DISCHARGE, RETURN AND LEAKAGE..................................................................................... 433 BLEED AIR FROM FUEL SYSTEM...................................................................................................... 438 Bleed air from fuel system.................................................................................................. 438 Test fuel system for leakage.................................................................................................... 440 Test fuel circuit for leakage............................................................................................... 440 CYLINDER CUT-OUT MODE OPERATION................................................................................................. 442 NO-INJECTION CRANKING OPERATION................................................................................................. 443 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 444 CHECK AIR CONDITIONER COMPRESSOR BELT....................................................................................... 444 ADJUST AIR CONDITIONER COMPRESSOR BELT...................................................................................... 444 POWER TRAIN......................................................................................................................... 446 Test swing circle bearing clearance............................................................................................. 446 Test swing circle bearing clearance......................................................................................... 446 UNDERCARRIAGE AND FRAME............................................................................................................. 447 Test and adjust track shoe tension.............................................................................................. 447 Test track shoe tension..................................................................................................... 447 Adjust track shoe tension................................................................................................... 447 HYDRAULIC SYSTEM.................................................................................................................... 449 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 449 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK.............................................................................. 449 Release remaining pressure in hydraulic cylinder circuit.................................................................... 449 Release remaining pressure for machines without anti-drop valve............................................................. 449 Release remaining pressure for machines with boom anti-drop valve........................................................... 449 Release remaining pressure from swing motor circuit......................................................................... 451 RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT........................................................................ 451 Test and adjust oil pressure in work equipment, swing, and travel circuits...................................................... 452 Test oil pressure in work equipment, swing, and travel circuits............................................................. 452 Adjust oil pressure in work equipment, swing, and travel circuits........................................................... 459 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 462 Test oil pressure of control circuit........................................................................................ 462 Test and adjust oil pressure in pump PC control circuit......................................................................... 464 Test PC valve outlet pressure (servo piston inlet pressure)................................................................. 464 TEST PC-EPC VALVE OUTLET PRESSURE........................................................................................... 465 Adjust oil pressure in pump PC control circuit.............................................................................. 467 Test and adjust oil pressure in pump LS control circuit......................................................................... 468 Test LS differential pressure with machine monitor.......................................................................... 468 Test LS differential pressure by testing tool............................................................................... 470 Test LS valve outlet pressure (servo piston inlet pressure)................................................................. 472 Test LS-EPC valve outlet pressure........................................................................................... 473 Adjust LS valve............................................................................................................. 474 Test outlet pressure of solenoid valve.......................................................................................... 476 Test outlet pressure of solenoid valve...................................................................................... 476 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 478 Test PPC valve outlet pressure.................................................................................................. 480 Test outlet pressure of PPC valve with machine monitor...................................................................... 480 TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL........................................................................... 481 Adjust play of work equipment and swing PPC valve............................................................................... 483 Adjust play of work equipment and swing PPC valve........................................................................... 483 TesTest pump swash plate sensor................................................................................................. 484 Test pump swash plate sensor................................................................................................ 484 Test parts causing hydraulic drift in work equipment............................................................................ 485 Test parts causing hydraulic drift of boom cylinder and bucket cylinder..................................................... 485 Test parts causing hydraulic drift of arm cylinder.......................................................................... 485 Test parts causing hydraulic drift of boom hydraulic drift prevention valve................................................. 486 Test parts causing hydraulic drift of PPC valve............................................................................. 486 Test oil leakage................................................................................................................ 487 TEST OIL LEAKAGE FROM BOOM CYLINDER......................................................................................... 487 TEST OIL LEAKAGE FROM ARM CYLINDER.......................................................................................... 488 TEST OIL LEAKAGE FROM BUCKET CYLINDER....................................................................................... 489 Test oil leakage from swing motor........................................................................................... 489 Test oil leakage from travel motor.......................................................................................... 490 Bleed air from hydraulic system................................................................................................. 492 Bleed air from main pump.................................................................................................... 493 BLEED AIR FROM CYLINDER..................................................................................................... 494 BLEED AIR FROM SWING MOTOR.................................................................................................. 495 BLEED AIR FROM TRAVEL MOTOR................................................................................................. 495 CAB RELATED PARTS................................................................................................................... 497 Test cab tipping stopper........................................................................................................ 497 Test cab tipping stopper.................................................................................................... 497 ADJUST MIRRORS.................................................................................................................. 498 ADJUST MACHINE LEFT FRONT MIRROR (A)........................................................................................ 498 Adjust regular position of machine left front mirror (A).................................................................... 499 ADJUST MACHINE RIGHT FRONT MIRROR (B)....................................................................................... 500 ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)................................................................... 500 ADJUST MACHINE RIGHT SIDE MIRROR (C)........................................................................................ 501 ELECTRICAL SYSTEM................................................................................................................... 503 SETTING AND OPERATION OF MACHINE MONITOR........................................................................................ 503 OPERATOR MODE............................................................................................................... 507 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 507 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 507 CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY).............................................................................. 508 CHECK FUNCTION OF SERVICE METER............................................................................................. 508 SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD........................................................................ 508 SERVICE MODE................................................................................................................ 511 Operation of service mode................................................................................................... 511 Check pre-defined monitoring information.................................................................................... 512 CHECK MONITORING INFORMATION................................................................................................ 516 ABNORMALITY RECORD MENU..................................................................................................... 524 CHECK MAINTENANCE RECORD.................................................................................................... 527 MAINTENANCE MODE SETTING.................................................................................................... 529 Phone number entry setting.................................................................................................. 533 DEFAULT SETTING MENU........................................................................................................ 534 TESTING MENU................................................................................................................ 542 ADJUSTMENT MENU............................................................................................................. 544 NO-INJECTION CRANKING OPERATION............................................................................................. 561 KOMTRAX SETTINGS MENU....................................................................................................... 563 Display service message..................................................................................................... 565 START UP KOMTRAX TERMINAL....................................................................................................... 566 Adjust rearview camera angle.................................................................................................... 570 ADJUST REARVIEW CAMERA ANGLE................................................................................................ 570 ENGINE CONTROLLER VOLTAGE CIRCUIT............................................................................................... 572 TEST DIODES..................................................................................................................... 573 TEST DIODES BY DIGITAL TESTER............................................................................................... 573 TEST DIODES BY ANALOG TESTER................................................................................................ 573 Pm-CLINIC........................................................................................................................... 574 PM CLINIC SERVICE............................................................................................................... 574 PM CLINIC CHECK SHEET: PC210-10M0........................................................................................... 577 PM CLINIC CHECK SHEET: PC210LC-10M0......................................................................................... 585 40 TROUBLESHOOTING...................................................................................................................... 593 ABBREVIATION LIST................................................................................................................... 594 CONTENTS............................................................................................................................ 599 RELATED INFORMATION TO TROUBLESHOOT................................................................................................. 605 PRECAUTIONS FOR TROUBLESHOOTING................................................................................................. 605 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 606 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 608 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 610 WALK-AROUND CHECK........................................................................................................... 610 TEST ENGINE RELATED PARTS................................................................................................... 611 TEST WORK EQUIPMENT AND UNDERCARRIAGE....................................................................................... 613 CHECK ELECTRIC EQUIPMENT.................................................................................................... 614 CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER...................................................................................... 619 CONNECT ADAPTER TO TROUBLESHOOT MONITOR..................................................................................... 619 CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER............................................................................. 621 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL............................................................................ 625 CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER........................................................................... 627 CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR............................................................... 628 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH.............................................................................. 630 DISCONNECT AND CONNECT DEUTSCH CONNECTOR.................................................................................... 630 DISCONNECT AND CONNECT BOSCH CONNECTOR...................................................................................... 630 DISCONNECT AND CONNECT AMP CONNECTOR........................................................................................ 631 DISCONNECT AND CONNECT SUMITOMO CONNECTOR................................................................................... 632 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL.............................................................................. 633 DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR............................................................... 633 DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR..................................................................................... 634 DISCONNECT AND CONNECT FRAMATOME CONNECTOR.................................................................................. 634 DISCONNECT AND CONNECT TYCO CONNECTOR....................................................................................... 635 DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE......................................................................... 636 PROCEDURE FOR TROUBLESHOOTING................................................................................................... 637 INFORMATION DESCRIBED IN TROUBLESHOOTING........................................................................................ 638 DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS........................................................ 641 CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE............................................................................... 644 CONNECTOR LAYOUT................................................................................................................ 718 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 724 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 766 FUSE LOCATION AND CONNECTION TABLE.............................................................................................. 772 DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING............................................................... 775 FAILURE CODES TABLE............................................................................................................. 777 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................... 785 FAILURE CODE [602KNX]........................................................................................................... 785 FAILURE CODE [6AZ0ZG]........................................................................................................... 788 FAILURE CODE [879AKA]........................................................................................................... 792 FAILURE CODE [879AKB]........................................................................................................... 794 FAILURE CODE [879BKA]........................................................................................................... 796 FAILURE CODE [879BKB]........................................................................................................... 799 FAILURE CODE [879CKA]........................................................................................................... 802 FAILURE CODE [879CKB]........................................................................................................... 804 FAILURE CODE [879DKZ]........................................................................................................... 806 FAILURE CODE [879EMC]........................................................................................................... 810 FAILURE CODE [879FMC]........................................................................................................... 812 FAILURE CODE [879GKX]........................................................................................................... 814 FAILURE CODE [989L00]........................................................................................................... 817 FAILURE CODE [989M00]........................................................................................................... 819 FAILURE CODE [989N00]........................................................................................................... 821 FAILURE CODE [AA10NX]........................................................................................................... 822 FAILURE CODE [AB00KE]........................................................................................................... 825 FAILURE CODE [B@BAZG]........................................................................................................... 829 FAILURE CODE [B@BAZK]........................................................................................................... 833 FAILURE CODE [B@BCZK]........................................................................................................... 836 FAILURE CODE [B@BCNS]........................................................................................................... 838 FAILURE CODE [B@BCQA]........................................................................................................... 842 FAILURE CODE [B@HANS]........................................................................................................... 844 FAILURE CODE [CA111]............................................................................................................ 846 FAILURE CODE [CA115]............................................................................................................ 851 ENGINE Ne (CRANKSHAFT) SPEED SENSOR......................................................................................... 857 FAILURE CODE [CA122]............................................................................................................ 859 FAILURE CODE [CA123]............................................................................................................ 862 FAILURE CODE [CA131]............................................................................................................ 866 FAILURE CODE [CA132]............................................................................................................ 869 FAILURE CODE [CA144]............................................................................................................ 873 FAILURE CODE [CA145]............................................................................................................ 877 FAILURE CODE [CA153]............................................................................................................ 881 FAILURE CODE [CA154]............................................................................................................ 885 FAILURE CODE [CA155]............................................................................................................ 889 FAILURE CODE [CA187]............................................................................................................ 891 FAILURE CODE [CA221]............................................................................................................ 894 FAILURE CODE [CA222]............................................................................................................ 897 FAILURE CODE [CA227]............................................................................................................ 900 FAILURE CODE [CA234]............................................................................................................ 903 FAILURE CODE [CA238]............................................................................................................ 905 FAILURE CODE [CA271]............................................................................................................ 908 FAILURE CODE [CA272]............................................................................................................ 911 FAILURE CODE [CA322]............................................................................................................ 913 FAILURE CODE [CA323]............................................................................................................ 917 FAILURE CODE [CA324]............................................................................................................ 921 FAILURE CODE [CA325]............................................................................................................ 925 FAILURE CODE [CA331]............................................................................................................ 929 FAILURE CODE [CA332]............................................................................................................ 933 FAILURE CODE [CA342]............................................................................................................ 937 FAILURE CODE [CA351]............................................................................................................ 942 FAILURE CODE [CA352]............................................................................................................ 947 FAILURE CODE [CA386]............................................................................................................ 950 FAILURE CODE [CA435]............................................................................................................ 952 FAILURE CODE [CA441]............................................................................................................ 955 FAILURE CODE [CA442]............................................................................................................ 960 FAILURE CODE [CA449]............................................................................................................ 964 FAILURE CODE [CA451]............................................................................................................ 970 FAILURE CODE [CA452]............................................................................................................ 973 FAILURE CODE [CA488]............................................................................................................ 976 FAILURE CODE [CA553]............................................................................................................ 979 FAILURE CODE [CA559]............................................................................................................ 984 TEST LOW PRESSURE FUEL CIRCUIT DEVICES...................................................................................... 990 FAILURE CODE [CA689]............................................................................................................ 992 FAILURE CODE [CA731]............................................................................................................ 997 INSTALLATION POINTS OF CRANKSHAFT AND CAMSHAFT SPEED SENSORS................................................................1000 FAILURE CODE [CA757]............................................................................................................1002 FAILURE CODE [CA778]............................................................................................................1007 ENGINE Ne (CRANKSHAFT) SPEED SENSOR.........................................................................................1012 FAILURE CODE [CA2185]...........................................................................................................1014 FAILURE CODE [CA2186]...........................................................................................................1016 FAILURE CODE [CA2249]...........................................................................................................1019 TEST LOW PRESSURE FUEL CIRCUIT DEVICES......................................................................................1025 FAILURE CODE [CA2311]...........................................................................................................1027 FAILURE CODE [CA2555]...........................................................................................................1034 FAILURE CODE [CA2556]...........................................................................................................1038 FAILURE CODE [D110KB]...........................................................................................................1042 FAILURE CODE [D19JKZ]...........................................................................................................1045 FAILURE CODE [D1N0KA]...........................................................................................................1050 FAILURE CODE [D1N0KB]...........................................................................................................1052 FAILURE CODE [D1N0KY]...........................................................................................................1054 FAILURE CODE [D811MC]...........................................................................................................1055 FAILURE CODE [D862KA]...........................................................................................................1056 FAILURE CODE [D8AQKR]...........................................................................................................1058 FAILURE CODE [D8ALKA]...........................................................................................................1066 FAILURE CODE [D8ALKB]...........................................................................................................1070 FAILURE CODE [DA20MC]...........................................................................................................1073 FAILURE CODE [DA22KK]...........................................................................................................1074 FAILURE CODE [DA25KP]...........................................................................................................1079 FAILURE CODE [DA26KP]...........................................................................................................1083 FAILURE CODE [DA29KQ]...........................................................................................................1089 FAILURE CODE [DA2LKA]...........................................................................................................1094 FAILURE CODE [DA2LKB]...........................................................................................................1098 FAILURE CODE [DA2QKR]...........................................................................................................1101 FAILURE CODE [DA2RKR]...........................................................................................................1110 FAILURE CODE [DAF0MB]...........................................................................................................1118 FAILURE CODE [DAF0MC]...........................................................................................................1119 FAILURE CODE [DAF9KQ]...........................................................................................................1120 FAILURE CODE [DAFGMC]...........................................................................................................1122 FAILURE CODE [DAFLKA]...........................................................................................................1123 FAILURE CODE [DAFLKB]...........................................................................................................1127 FAILURE CODE [DAFQKR]...........................................................................................................1130 FAILURE CODE [DAZ9KQ]...........................................................................................................1139 FAILURE CODE [DAZQKR]...........................................................................................................1141 FAILURE CODE [DB2QKR]...........................................................................................................1149 FAILURE CODE [DDPAKA]...........................................................................................................1158 FAILURE CODE [DGH2KA]...........................................................................................................1161 FAILURE CODE [DGH2KB]...........................................................................................................1164 FAILURE CODE [DHA4KA]...........................................................................................................1167 FAILURE CODE [DHE5MA]...........................................................................................................1170 FAILURE CODE [DHPAMA]...........................................................................................................1174 FAILURE CODE [DHPBMA]...........................................................................................................1178 FAILURE CODE [DHS3MA]...........................................................................................................1182 FAILURE CODE [DHS4MA]...........................................................................................................1186 FAILURE CODE [DHS8MA]...........................................................................................................1190 FAILURE CODE [DHS9MA]...........................................................................................................1194 FAILURE CODE [DHSAMA]...........................................................................................................1198 FAILURE CODE [DHSBMA]...........................................................................................................1202 FAILURE CODE [DHSCMA]...........................................................................................................1206 FAILURE CODE [DHSDMA]...........................................................................................................1210 FAILURE CODE [DHSFMA]...........................................................................................................1214 FAILURE CODE [DHSGMA]...........................................................................................................1218 FAILURE CODE [DHSHMA]...........................................................................................................1222 FAILURE CODE [DHSJMA]...........................................................................................................1226 FAILURE CODE [DJG1KX]...........................................................................................................1230 FAILURE CODE [DKR0MA]...........................................................................................................1234 FAILURE CODE [DKR1MA]...........................................................................................................1238 FAILURE CODE [DKR2MA]...........................................................................................................1242 FAILURE CODE [DKR2NX]...........................................................................................................1246 FAILURE CODE [DLM5KA]...........................................................................................................1248 FAILURE CODE [DLM5MB]...........................................................................................................1252 FAILURE CODE [DR21KX]...........................................................................................................1256 FAILURE CODE [DR31KX]...........................................................................................................1259 FAILURE CODE [DV20KB]...........................................................................................................1260 FAILURE CODE [DW43KA]...........................................................................................................1263 FAILURE CODE [DW43KB]...........................................................................................................1266 FAILURE CODE [DW43KY]...........................................................................................................1269 FAILURE CODE [DW45KA]...........................................................................................................1271 FAILURE CODE [DW45KB]...........................................................................................................1275 FAILURE CODE [DW45KY]...........................................................................................................1279 FAILURE CODE [DW91KA]...........................................................................................................1282 FAILURE CODE [DW91KB]...........................................................................................................1284 FAILURE CODE [DW91KY]...........................................................................................................1287 FAILURE CODE [DW97KA]...........................................................................................................1289 FAILURE CODE [DW97KB]...........................................................................................................1291 FAILURE CODE [DW97KY]...........................................................................................................1294 FAILURE CODE [DWA2KA]...........................................................................................................1296 FAILURE CODE [DWA2KB]...........................................................................................................1298 FAILURE CODE [DWA2KY]...........................................................................................................1301 FAILURE CODE [DWK0KA]...........................................................................................................1303 FAILURE CODE [DWK0KB]...........................................................................................................1305 FAILURE CODE [DWK0KY]...........................................................................................................1308 FAILURE CODE [DWK2KA]...........................................................................................................1310 FAILURE CODE [DWK2KB]...........................................................................................................1312 FAILURE CODE [DWK2KY]...........................................................................................................1315 FAILURE CODE [DWK8KA]...........................................................................................................1317 FAILURE CODE [DWK8KB]...........................................................................................................1319 FAILURE CODE [DWK8KY]...........................................................................................................1322 FAILURE CODE [DWN5KA]...........................................................................................................1324 FAILURE CODE [DWN5KB]...........................................................................................................1327 FAILURE CODE [DWN5KY]...........................................................................................................1330 FAILURE CODE [DXA8KA]...........................................................................................................1332 FAILURE CODE [DXA8KB]...........................................................................................................1335 FAILURE CODE [DXA9KA]...........................................................................................................1339 FAILURE CODE [DXA9KB]...........................................................................................................1342 FAILURE CODE [DXE0KA]...........................................................................................................1346 FAILURE CODE [DXE0KB]...........................................................................................................1348 FAILURE CODE [DXE4KA]...........................................................................................................1351 FAILURE CODE [DXE4KB]...........................................................................................................1353 FAILURE CODE [DXE4KY]...........................................................................................................1356 FAILURE CODE [DXE5KA]...........................................................................................................1358 FAILURE CODE [DXE5KB]...........................................................................................................1360 FAILURE CODE [DXE6KA]...........................................................................................................1363 FAILURE CODE [DXE6KB]...........................................................................................................1365 FAILURE CODE [DY20KA]...........................................................................................................1368 FAILURE CODE [DY20MA]...........................................................................................................1372 FAILURE CODE [DY2CKB]...........................................................................................................1376 FAILURE CODE [DY2DKB]...........................................................................................................1381 FAILURE CODE [DY2EKB]...........................................................................................................1384 FAILURE CODE [F@BBZL]...........................................................................................................1387 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1390 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...................................................................................1390 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................................................1400 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK.......................................................................................1404 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP..........................................................1408 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.................................................1413 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW..........1418 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW....1420 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION.......................................................1422 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION........................................................1424 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION....................................................1426 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION..............................................................1428 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION................................................................1432 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...........................................................1433 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION................................................1434 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.......................................................1436 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.................................................1437 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM................................................................................1439 FUEL GAUGE INDICATES INCORRECT LEVEL............................................................................................1442 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM.................................................................1444 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE.......................................................................1445 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM...........................................................1447 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE.................................................................1450 MACHINE MONITOR SHOWS INCORRECT MODEL...........................................................................................1452 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED..........................................................................1453 FUNCTION SWITCH DOES NOT OPERATE................................................................................................1454 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER).....................................................................1455 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED................................1457 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION..................................................1458 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED....................................................1461 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED.....................................................1462 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED......................................................1463 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED......................................................................1464 ALARM BUZZER DOES NOT STOP......................................................................................................1466 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION.........................................................1467 MACHINE DOES NOT CHANGE TO SERVICE MODE.........................................................................................1468 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE............................................................................1469 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK...............................................................................1473 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED.....................................................1475 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON...................................................................1479 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY.......................................1482 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED.............................................................................1486 TRAVEL ALARM DOES NOT SOUND.....................................................................................................1488 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS...................................................................................1491 HORN DOES NOT SOUND.............................................................................................................1493 HORN DOES NOT STOP..............................................................................................................1497 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED........................................................1499 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED............................................................................1500 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED............................................................1503 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.......................................................................1506 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.......................................................................1507 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.....................................................................1508 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION...........................................................................1509 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.................................................................1510 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.................................................................1511 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION............................................................................1512 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION...........................................................................1513 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION..................................................................1514 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................1517 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY........................................................................................1519 QUICK COUPLER DOES NOT WORK.....................................................................................................1521 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1526 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE).........................................................................1526 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK...............................................................................1527 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER......................................................................1529 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR....................................................................................1542 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...............................................................................1547 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS......................................................................................1549 BOOM SPEED OR POWER IS LOW......................................................................................................1558 Arm speed or power is low.......................................................................................................1570 BUCKET SPEED OR POWER IS LOW....................................................................................................1581 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION................................................................................1591 HYDRAULIC DRIFT OF BOOM IS LARGE................................................................................................1595 HYDRAULIC DRIFT OF ARM IS LARGE.................................................................................................1597 HYDRAULIC DRIFT OF BUCKET IS LARGE..............................................................................................1601 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES................................................1604 TIME LAG OF WORK EQUIPMENT IS LARGE.............................................................................................1606 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE............................................................................1613 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................1616 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED................................................................................1618 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER...............................................1620 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY...........................................................1622 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW...........................................................1623 MACHINE DOES NOT TRAVEL STRAIGHT................................................................................................1624 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW............................................................................1635 TRAVEL SPEED IS SLOW............................................................................................................1650 ONE OF TRACKS DOES NOT RUN......................................................................................................1661 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST...............................................................1670 MACHINE DOES NOT SWING TO RIGHT OR LEFT.........................................................................................1673 SWINGS ONLY IN ONE DIRECTION....................................................................................................1678 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)....................................................1681 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION..................................................................1688 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...............................................1692 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)...........................1694 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS.......................................................................................1698 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS.........................................................................1700 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)..........................................................1703 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED).........................................................1705 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE).......................................................................1709 UNUSUAL NOISE IS HEARD FROM AROUND FAN..........................................................................................1711 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1713 CONTENTS............................................................................................................................1714 ABBREVIATION LIST...................................................................................................................1718 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................1723 HOW TO READ THIS MANUAL.........................................................................................................1723 COATING MATERIALS LIST..........................................................................................................1725 SPECIAL TOOLS LIST..............................................................................................................1729 SKETCHES OF SPECIAL TOOLS.......................................................................................................1738 PREPARATION.........................................................................................................................1744 DRAIN AND ADD COOLANT...........................................................................................................1744 DRAIN COOLANT...............................................................................................................1744 ADD COOLANT.................................................................................................................1745 DRAIN AND AD HYDRAULIC OIL......................................................................................................1747 DRAIN HYDRAULIC OIL.........................................................................................................1747 ADD HYDRAULIC OIL...........................................................................................................1748 DRAIN AND ADD FUEL..............................................................................................................1750 DRAIN FUEL..................................................................................................................1750 ADD FUEL....................................................................................................................1751 COLLECT AND REFILL REFRIGERANT..................................................................................................1754 COLLECT REFRIGERANT.........................................................................................................1754 REFILL REFRIGERANT..........................................................................................................1754 ENGINE AND COOLING SYSTEM...........................................................................................................1755 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................1755 REMOVE SUPPLY PUMP ASSEMBLY.................................................................................................1756 INSTALL SUPPLY PUMP ASSEMBLY................................................................................................1760 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................1764 REMOVE INJECTOR ASSEMBLY....................................................................................................1765 INSTALL INJECTOR ASSEMBLY...................................................................................................1768 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................1775 REMOVE CYLINDER HEAD ASSEMBLY...............................................................................................1776 INSTALL CYLINDER HEAD ASSEMBLY..............................................................................................1787 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY......................................................................................1802 REMOVE STARTING MOTOR ASSEMBLY..............................................................................................1802 INSTALL STARTING MOTOR ASSEMBLY.............................................................................................1804 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................1807 REMOVE ALTERNATOR BELT......................................................................................................1807 INSTALL ALTERNATOR BELT.....................................................................................................1811 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................1814 REMOVE RADIATOR ASSEMBLY....................................................................................................1814 INSTALL RADIATOR ASSEMBLY...................................................................................................1817 REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY....................................................................................1820 REMOVE HYDRAULIC COOLER ASSEMBLY............................................................................................1821 INSTALL HYDRAULIC COOLER ASSEMBLY...........................................................................................1824 REMOVE AND INSTALL AFTER COOLER ASSEMBLY........................................................................................1827 REMOVE AFTER COOLER ASSEMBLY................................................................................................1827 INSTALL AFTER COOLER ASSEMBLY...............................................................................................1829 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY..........................................................................................1833 REMOVE FAN CLUTCH ASSEMBLY..................................................................................................1834 INSTALL FAN CLUTCH ASSEMBLY.................................................................................................1838 REMOVE AND INSTALL FAN..........................................................................................................1844 REMOVE FAN..................................................................................................................1844 INSTALL FAN.................................................................................................................1844 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................1846 REMOVE ENGINE AND MAIN PUMP ASSEMBLY........................................................................................1847 INSTALL ENGINE AND MAIN PUMP ASSEMBLY.......................................................................................1863 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................1880 REMOVE ENGINE FRONT OIL SEAL................................................................................................1880 INSTALL ENGINE FRONT OIL SEAL...............................................................................................1883 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................1886 REMOVE ENGINE REAR OIL SEAL.................................................................................................1886 INSTALL ENGINE REAR OIL SEAL................................................................................................1888 REMOVE AND INSTALL FUEL COOLER ASSEMBLY.........................................................................................1892 REMOVE FUEL COOLER ASSEMBLY.................................................................................................1892 INSTALL FUEL COOLER ASSEMBLY................................................................................................1893 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................1895 REMOVE ENGINE HOOD ASSEMBLY.................................................................................................1895 INSTALL ENGINE HOOD ASSEMBLY................................................................................................1897 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................1899 REMOVE FUEL TANK ASSEMBLY...................................................................................................1900 INSTALL FUEL TANK ASSEMBLY..................................................................................................1904 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................1910 REMOVE AIR CLEANER ASSEMBLY.................................................................................................1910 INSTALL AIR CLEANER ASSEMBLY................................................................................................1912 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................1914 REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................1914 INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.................................................................................1917 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................1920 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY...................................................................................1920 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY..................................................................................1922 POWER TRAIN.........................................................................................................................1924 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................1924 REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY................................................................................1925 INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...............................................................................1927 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................1929 DISASSEMBLE FINAL DRIVE ASSEMBLY............................................................................................1930 ASSEMBLE FINAL DRIVE ASSEMBLY...............................................................................................1935 REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY....................................................................1947 REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY.............................................................................1948 INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................................1950 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................1954 DISASSEMBLE SWING MACHINERY ASSEMBLY........................................................................................1955 ASSEMBLE SWING MACHINERY ASSEMBLY...........................................................................................1961 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................1970 REMOVE SWING CIRCLE ASSEMBLY................................................................................................1970 INSTALL SWING CIRCLE ASSEMBLY...............................................................................................1971 UNDERCARRIAGE AND FRAME.............................................................................................................1972 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................1972 SEPARATE TRACK ASSEMBLY.....................................................................................................1972 INSTALL TRACK ASSEMBLY......................................................................................................1975 REMOVE AND INSTALL SPROCKET.....................................................................................................1979 REMOVE SPROCKET.............................................................................................................1979 INSTALL SPROCKET............................................................................................................1980 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................1981 REMOVE IDLER AND IDLER CUSHION ASSEMBLY.....................................................................................1981 INSTALL IDLER AND IDLER CUSHION ASSEMBLY....................................................................................1982 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................1984 DISASSEMBLE IDLER ASSEMBLY..................................................................................................1984 ASSEMBLE IDLER ASSEMBLY.....................................................................................................1986 DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY.................................................................................1993 DISASSEMBLE IDLER CUSHION ASSEMBLY..........................................................................................1994 ASSEMBLE IDLER CUSHION ASSEMBLY.............................................................................................1995 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................1997 DISASSEMBLE TRACK ROLLER ASSEMBLY...........................................................................................1998 ASSEMBLE TRUCK ROLLER ASSEMBLY..............................................................................................1999 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY................................................................................2001 DISASSEMBLE CARRIER ROLLER ASSEMBLY.........................................................................................2001 ASSEMBLE CARRIER ROLLER ASSEMBLY............................................................................................2003 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2006 REMOVE REVOLVING FRAME ASSEMBLY.............................................................................................2007 INSTALL REVOLVING FRAME ASSEMBLY............................................................................................2010 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2013 REMOVE COUNTERWEIGHT ASSEMBLY...............................................................................................2013 INSTALL COUNTERWEIGHT ASSEMBLY..............................................................................................2014 HYDRAULIC SYSTEM....................................................................................................................2016 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2016 REMOVE CENTER SWIVEL JOINT ASSEMBLY.........................................................................................2017 INSTALL CENTER SWIVEL JOINT ASSEMBLY........................................................................................2020 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2024 DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY....................................................................................2025 ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY.......................................................................................2026 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2028 REMOVE HYDRAULIC TANK ASSEMBLY..............................................................................................2029 INSTALL HYDRAULIC TANK ASSEMBLY.............................................................................................2033 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2039 REMOVE MAIN PUMP ASSEMBLY...................................................................................................2040 INSTALL MAIN PUMP ASSEMBLY..................................................................................................2047 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2054 REMOVE CONTROL VALVE ASSEMBLY...............................................................................................2055 INSTALL CONTROL VALVE ASSEMBLY..............................................................................................2067 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2080 REPLACE PRESSURE COMPENSATION VALVE SEAL RING...............................................................................2081 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2083 DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...............................................................................2084 ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................................2084 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2086 DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY.......................................................................................2086 ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..........................................................................................2087 WORK EQUIPMENT......................................................................................................................2089 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2089 REMOVE WORK EQUIPMENT ASSEMBLY..............................................................................................2090 INSTALL WORK EQUIPMENT ASSEMBLY.............................................................................................2093 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2096 DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY................................................................................2097 ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................................2102 CAB RELATED PARTS...................................................................................................................2111 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY........................................................................................2111 REMOVE OPERATOR CAB ASSEMBLY................................................................................................2112 INSTALL OPERATOR CAB ASSEMBLY...............................................................................................2122 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2132 REMOVE OPERATOR CAB GLASS (ADHERED GLASS)...................................................................................2134 INSTALL OPERATOR CAB GLASS (ADHERED GLASS)..................................................................................2134 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2145 REMOVE FRONT WINDOW ASSEMBLY................................................................................................2146 INSTALL FRONT WINDOW ASSEMBLY...............................................................................................2149 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2155 REMOVE FLOOR FRAME ASSEMBLY.................................................................................................2156 INSTALL FLOOR FRAME ASSEMBLY................................................................................................2162 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2170 REMOVE AIR CONDITIONER UNIT ASSEMBLY........................................................................................2171 INSTALL AIR CONDITIONER UNIT ASSEMBLY.......................................................................................2179 REMOVE AND INSTALL OPERATOR SEAT................................................................................................2187 REMOVE OPERATOR SEAT........................................................................................................2187 INSTALL OPERATOR SEAT.......................................................................................................2188 REMOVE AND INSTALL SEATBELT.....................................................................................................2190 REMOVE SEATBELT.............................................................................................................2190 INSTALL SEATBELT............................................................................................................2191 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2192 REMOVE FRONT WIPER ASSEMBLY.................................................................................................2192 INSTALL FRONT WIPER ASSEMBLY................................................................................................2198 ELECTRICAL SYSTEM...................................................................................................................2206 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2206 REMOVE ENGINE CONTROLLER ASSEMBLY...........................................................................................2206 INSTALL ENGINE CONTROLLER ASSEMBLY..........................................................................................2208 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2210 REMOVE PUMP CONTROLLER ASSEMBLY.............................................................................................2210 INSTALL PUMP CONTROLLER ASSEMBLY............................................................................................2212 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2216 REMOVE MACHINE MONITOR ASSEMBLY.............................................................................................2216 INSTALL MACHINE MONITOR ASSEMBLY............................................................................................2219 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2223 REMOVE PUMP SWASH PLATE SENSOR..............................................................................................2223 INSTALL PUMP SWASH PLATE SENSOR.............................................................................................2225 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................2228 REMOVE KOMTRAX TERMINAL ASSEMBLY............................................................................................2228 INSTALL KOMTRAX TERMINAL ASSEMBLY...........................................................................................2231 60 MAINTENANCE STANDARD.................................................................................................................2235 CONTENTS............................................................................................................................2236 ABBREVIATION LIST...................................................................................................................2237 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.......................................................................................2242 ENGINE AND COOLING SYSTEM...........................................................................................................2244 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2244 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2245 POWER TRAIN.........................................................................................................................2247 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2247 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2248 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2251 MAINTENANCE STANDARD OF SPROCKET................................................................................................2253 SPROCKET TOOTH PROFILE FULL-SCALE DRAWING.......................................................................................2254 UNDERCARRIAGE AND FRAME.............................................................................................................2255 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2255 MAINTENANCE STANDARD OF IDLER...................................................................................................2256 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2258 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2260 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2261 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2264 MAINTENANCE STANDARD OF SWAMP SHOE..............................................................................................2265 MAINTENANCE STANDARD OF ROAD LINER..............................................................................................2266 HYDRAULIC SYSTEM....................................................................................................................2267 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2267 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2268 MAINTENANCE STANDARD OF LS-EPC VALVE............................................................................................2270 MAINTENANCE STANDARD OF PC-EPC VALVE............................................................................................2271 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2272 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2274 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2277 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2287 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2290 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2293 MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE..................................................................2294 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................2295 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2296 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...................................................2298 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)....................................................2299 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2300 WORK EQUIPMENT......................................................................................................................2301 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2301 DIMENSIONS OF ARM...............................................................................................................2307 DIMENSIONS OF BUCKET............................................................................................................2309 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2311 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2312 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2313 80 OTHERS...............................................................................................................................2315 ABBREVIATION........................................................................................................................2316 AIR CONDITIONER SYSTEM..............................................................................................................2321 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2321 LAYOUT DRAWING OF AIR CONDITIONER SYSTEM........................................................................................2322 SPECIFICATION OF AIR CONDITIONER................................................................................................2324 CONFIGURATION OF REFRIGERATION CYCLE............................................................................................2325 FUNCTION OF REFRIGERATION CYCLE.................................................................................................2326 SYSTEM DIAGRAM OF AIR CONDITIONER...................................................................................................2327 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2328 AIR CONDITIONER UNIT............................................................................................................2328 STRUCTURE OF AIR CONDITIONER UNIT...........................................................................................2328 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2329 COMPONENT PARTS OF AIR CONDITIONER UNIT.....................................................................................2330 AIR CONDITIONER CONTROLLER......................................................................................................2334 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2334 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2334 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER......................................................................2334 COMPRESSOR......................................................................................................................2336 STRUCTURE OF COMPRESSOR.....................................................................................................2336 SPECIFICATIONS OF COMPRESSOR................................................................................................2336 FUNCTION OF COMPRESSOR......................................................................................................2336 OPERATION OF COMPRESSOR.....................................................................................................2336 CONDENSER.......................................................................................................................2337 STRUCTURE OF CONDENSER......................................................................................................2337 SPECIFICATIONS OF CONDENSOR.................................................................................................2337 FUNCTION OF COMPRESSOR......................................................................................................2337 AIR CONDITIONER RELATED SENSORS.................................................................................................2339 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2339 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2339 STRUCTURE OF OUTSIDE TEMPERATURE SENSOR.....................................................................................2339 FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR..................................................................................2339 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER................................................................2340 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2343 TEST AIR LEAKAGE (DUCT CONNECTION)..................................................................................................2347 TEST AIR LEAKAGE (DUCT CONNECTION)..............................................................................................2347 TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION.....................................................................................2350 TEST VENT (MODE) CHANGEOVER.........................................................................................................2351 TEST VENT (MODE) CHANGEOVER.....................................................................................................2351 TEST FRESH/RECIRC AIR CHANGEOVER....................................................................................................2353 TEST FRESH/RECIRC AIR CHANGEOVER................................................................................................2353 TEST SUNLIGHT SENSOR................................................................................................................2354 TEST SUNLIGHT SENSOR............................................................................................................2354 TEST DUAL PRESSURE SWITCH...........................................................................................................2355 TEST DUAL PRESSURE SWITCH.......................................................................................................2355 TEST RELAY..........................................................................................................................2356 TEST RELAY......................................................................................................................2356 SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS..............................................................................2358 PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER...................................................................................2359 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2360 FAILURE CODE [879AKA]...............................................................................................................2363 FAILURE CODE [879AKB]...............................................................................................................2365 FAILURE CODE [879BKA]...............................................................................................................2367 FAILURE CODE [879BKB]...............................................................................................................2370 FAILURE CODE [879CKA]...............................................................................................................2373 FAILURE CODE [879CKB]...............................................................................................................2375 FAILURE CODE [879DKZ]...............................................................................................................2377 FAILURE CODE [879EMC]...............................................................................................................2381 FAILURE CODE [879FMC]...............................................................................................................2383 FAILURE CODE [879GKX]...............................................................................................................2385 AIR CONDITIONER DOES NOT OPERATE....................................................................................................2388 DEFECTIVE COOLING...................................................................................................................2391 HEATER DOES NOT OPERATE.............................................................................................................2400 COOL AIR DOES NOT COME OUT..........................................................................................................2404 NO AIR COMES OUT OR AIR FLOW IS ABNORMAL............................................................................................2410 FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE............................................................................................2414 CONNECT SERVICE TOOL................................................................................................................2418 CONNECT SERVICE TOOL............................................................................................................2419 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING..............................................................2420 HANDLE COMPRESSOR OIL...............................................................................................................2422 REPLACE DESICCANT...................................................................................................................2424 90 CIRCUIT DIAGRAMS.....................................................................................................................2427 CONTENTS............................................................................................................................2428 ABBREVIATION LIST...................................................................................................................2429 HOW TO READ THE CODES FOR ELECTRIC CABLE............................................................................................2434 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2439 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2439 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................2443 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2445 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................2445 ELECTRICAL CIRCUIT DIAGRAM (1/7)................................................................................................2449 ELECTRICAL CIRCUIT DIAGRAM (2/7)................................................................................................2451 ELECTRICAL CIRCUIT DIAGRAM (3/7)................................................................................................2453 ELECTRICAL CIRCUIT DIAGRAM (4/7)................................................................................................2455 ELECTRICAL CIRCUIT DIAGRAM (5/7)................................................................................................2457 ELECTRICAL CIRCUIT DIAGRAM (6/7)................................................................................................2459 ELECTRICAL CIRCUIT DIAGRAM (7/7)................................................................................................2461 CONNECTOR AND WIRING HARNESS CHART..................................................................................................2463 CONNECTOR AND WIRING HARNESS CHART (1/11).......................................................................................2465 CONNECTOR AND WIRING HARNESS CHART (2/11).......................................................................................2467 CONNECTOR AND WIRING HARNESS CHART (3/11).......................................................................................2469 CONNECTOR AND WIRING HARNESS CHART (4/11).......................................................................................2471 CONNECTOR AND WIRING HARNESS CHART (5/11).......................................................................................2473 CONNECTOR AND WIRING HARNESS CHART (6/11).......................................................................................2475 CONNECTOR AND WIRING HARNESS CHART (7/11).......................................................................................2477 CONNECTOR AND WIRING HARNESS CHART (8/11).......................................................................................2479 CONNECTOR AND WIRING HARNESS CHART (9/11).......................................................................................2481 CONNECTOR AND WIRING HARNESS CHART (10/11)......................................................................................2483 CONNECTOR AND WIRING HARNESS CHART (11/11)......................................................................................2485 INDEX....................................................................................................................................2487
DESCRIPTION:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-C0 – 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 SPECIFICATIONS
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 adjustingmethod 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 THE OTHER INFORMATION
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 02/01/2025
