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KOMATSU PC210-11E0 PC210LC-11E0 PC210NLC-11E0 PC230NHD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00632 – PDF
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KOMATSU PC210-11E0 PC210LC-11E0 PC210NLC-11E0 PC230NHD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00632 – PDF DOWNLOAD
SERIAL NUMBERS
PC210-11E0 – K75350 and up
PC210LC-11E0 – K75350 and up
PC210NLC-11E0 – K75210 and up
PC230NHD-11E0 – K75008 and up
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KOMATSU PC210-11E0 PC210LC-11E0 PC210NLC-11E0 PC230NHD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00632 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC210-11E0 PC210LC-11E0 PC210NLC-11E0 PC230NHD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00632 – PDF DOWNLOAD
Language : English
Pages : 3006
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
PC210-11E0 – K75350 and up
PC210LC-11E0 – K75350 and up
PC210NLC-11E0 – K75210 and up
PC230NHD-11E0 – K75008 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC210-11E0 PC210LC-11E0 PC210NLC-11E0 PC230NHD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00632 – PDF DOWNLOAD
00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 22 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 28 HOW TO READ THE SHOP MANUAL..................................................................................................... 28 SAFETY NOTICE FOR OPERATION..................................................................................................... 30 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 38 ACTIONS IF FIRE OCCURS.......................................................................................................... 40 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.................................................................................... 41 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................... 42 METHOD FOR CHECKING ENGINE TYPE................................................................................................. 43 PRECAUTIONS FOR DEF............................................................................................................. 45 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.............................................................................. 45 PRECAUTIONS FOR ADDING...................................................................................................... 45 PRECAUTIONS FOR STORING..................................................................................................... 45 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE..................................................................................... 45 THE OTHER PRECAUTIONS....................................................................................................... 45 STORE AdBlue/DEF................................................................................................................ 46 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 47 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS......................................................................... 50 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................... 57 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 59 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 60 PRACTICAL USE OF KOMTRAX........................................................................................................ 61 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 62 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 62 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 63 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 64 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 66 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 70 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 73 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 74 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 76 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 77 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 81 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 84 CONVERSION TABLE................................................................................................................ 91 01 SPECIFICATIONS....................................................................................................................... 97 CONTENTS............................................................................................................................ 98 ABBREVIATION LIST................................................................................................................... 99 SPECIFICATIONS...................................................................................................................... 105 SPECIFICATION DRAWING........................................................................................................... 105 SPECIFICATION DRAWING: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0............................................... 105 WORKING RANGE DRAWINGS.......................................................................................................... 107 WORKING RANGE: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0....................................................... 107 SPECIFICATIONS.................................................................................................................. 108 SPECIFICATIONS: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0...................................................... 108 WEIGHT TABLE.................................................................................................................... 112 WEIGHT TABLE: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0........................................................ 112 TABLE OF FUEL, COOLANT, AND LUBRICANTS.......................................................................................... 114 10 STRUCTURE AND FUNCTION............................................................................................................... 115 CONTENTS............................................................................................................................ 116 ABBREVIATION LIST................................................................................................................... 120 UREA SCR SYSTEM..................................................................................................................... 126 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................... 127 UREA SCR SYSTEM DIAGRAM......................................................................................................... 132 FUNCTION OF UREA SCR SYSTEM..................................................................................................... 133 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................... 133 INDUCEMENT STRATEGY......................................................................................................... 135 COMPONENT PARTS OF UREA SCR SYSTEM.............................................................................................. 154 AdBlue/DEF MIXING TUBE...................................................................................................... 154 SCR ASSEMBLY................................................................................................................ 154 AdBlue/DEF TANK............................................................................................................. 157 AdBlue/DEF PUMP............................................................................................................. 159 AdBlue/DEF INJECTOR......................................................................................................... 160 AdBlue/DEF HOSE............................................................................................................. 161 AdBlue/DEF TANK HEATING VALVE............................................................................................... 162 BOOT-UP SYSTEM...................................................................................................................... 163 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 163 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 165 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 165 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 165 BATTERY DISCONNECT SWITCH....................................................................................................... 166 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 166 ENGINE SYSTEM....................................................................................................................... 167 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 167 SPECIFICATIONS OF ENGINE SYSTEM............................................................................................. 168 FUNCTION OF ENGINE SYSTEM................................................................................................... 168 ENGINE CONTROL SYSTEM........................................................................................................... 169 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................... 169 OPERATION OF ENGINE CONTROL SYSTEM.......................................................................................... 170 AUTO-DECELERATION SYSTEM........................................................................................................ 172 AUTO-DECELERATION SYSTEM DIAGRAM............................................................................................ 172 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 172 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 173 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 174 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM..................................................................................... 174 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 175 OVERHEAT PREVENTION SYSTEM...................................................................................................... 176 OVERHEAT PREVENTION SYSTEM DIAGRAM.......................................................................................... 176 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 177 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 179 TURBOCHARGER PROTECTION SYSTEM DIAGRAM...................................................................................... 179 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 180 AUTOMATIC IDLE STOP SYSTEM...................................................................................................... 181 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.......................................................................................... 181 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...................................................................................... 181 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................ 184 VGT......................................................................................................................... 184 EGR SYSTEM.................................................................................................................. 188 EGR VALVE................................................................................................................... 190 EGR COOLER.................................................................................................................. 192 KCCV SYSTEM................................................................................................................. 193 KCCV VENTILATOR............................................................................................................. 195 KDPF........................................................................................................................ 197 COOLING SYSTEM...................................................................................................................... 202 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 202 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 203 FAN SPEED CONTROL SYSTEM OF FAN CLUTCH.......................................................................................... 204 FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH.............................................................................. 204 FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH.......................................................................... 205 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH...................................................................................... 206 ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH.......................................................................... 206 FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH...................................................................... 206 COMPONENT PARTS OF COOLING SYSTEM............................................................................................... 208 FAN CLUTCH.................................................................................................................. 208 CONTROL SYSTEM...................................................................................................................... 209 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................ 209 MACHINE MONITOR SYSTEM.......................................................................................................... 212 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 212 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 212 KomVision SYSTEM................................................................................................................ 213 LAYOUT DRAWING OF KOMVISION SYSTEM.......................................................................................... 213 KomVision SYSTEM DIAGRAM.................................................................................................... 215 FUNCTION OF KomVision SYSTEM................................................................................................ 215 KomVision CONTROLLER........................................................................................................ 222 KomVision CAMERA............................................................................................................ 226 KOMTRAX SYSTEM.................................................................................................................. 227 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 227 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 227 PPC LEVERS...................................................................................................................... 228 LH PPC LEVER................................................................................................................ 228 RH PPC LEVER................................................................................................................ 229 AUTOMATIC GREASE SYSTEM......................................................................................................... 230 OUTLINE OF AUTO GREASE SYSTEM............................................................................................... 230 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................... 244 MACHINE MONITOR............................................................................................................. 244 KomVision CONTROLLER........................................................................................................ 258 KomVision CAMERA............................................................................................................ 262 GATEWAY FUNCTION CONTROLLER................................................................................................. 263 COMMUNICATION TERMINAL...................................................................................................... 266 PUMP CONTROLLER............................................................................................................. 268 RESISTOR FOR PC-EPC VALVE................................................................................................... 272 CAN TERMINATING RESISTOR.................................................................................................... 272 PPC OIL PRESSURE SWITCH..................................................................................................... 273 ENGINE CONTROLLER........................................................................................................... 274 FUEL CONTROL DIAL........................................................................................................... 280 SENSOR.......................................................................................................................... 282 STRUCTURE OF ENGINE OIL PRESSURE SWITCH..................................................................................... 282 FUNCTION OF ENGINE OIL PRESSURE SWITCH...................................................................................... 282 STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH...................................................................... 282 SPECIFICATIONS - QUICK COUPLER LOW PRESSURE WARNING SWITCH.................................................................. 283 FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH....................................................................... 283 STRUCTURE OF AUTO GREASE PRESSURE SWITCH.................................................................................... 283 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH................................................................................ 284 FUNCTION OF AUTO GREASE PRESSURE SWITCH..................................................................................... 284 STRUCTURE OF OVERLOAD CAUTION SENSOR........................................................................................ 284 SPECIFICATIONS - OVERLOAD CAUTION SENSOR.................................................................................... 284 FUNCTION OF OVERLOAD CAUTION SENSOR......................................................................................... 284 HYDRAULIC SYSTEM.................................................................................................................... 285 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 285 CLSS............................................................................................................................ 291 STRUCTURE OF CLSS........................................................................................................... 291 OPERATION OF UNLOAD VALVE AND LS PRESSURE................................................................................... 293 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL................................................................................... 294 PRESSURE COMPENSATION CONTROL............................................................................................... 307 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 310 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 310 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 311 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 316 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 316 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 317 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 319 HYDRAULIC TANK.............................................................................................................. 319 MAIN PUMP................................................................................................................... 321 PILOT OIL FILTER............................................................................................................ 347 CONTROL VALVE............................................................................................................... 347 WORK EQUIPMENT SYSTEM............................................................................................................... 404 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 404 STRUCTURE OF VALVE CONTROL...................................................................................................... 409 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 411 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 411 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 412 PPC LOCK SYSTEM................................................................................................................. 413 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 413 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 413 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................. 414 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM..................................................................... 414 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................. 414 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 415 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................................... 416 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................. 416 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................... 418 TOOL CONTROL SYSTEM............................................................................................................. 419 TOOL CONTROL SYSTEM DIAGRAM................................................................................................. 419 FUNCTION OF TOOL CONTROL SYSTEM............................................................................................. 420 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM........................................................................................ 421 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 421 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 426 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)....................................................................... 435 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)........................................................................ 437 1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE................................................................................... 440 2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE................................................................................... 442 ATTACHMENT BYPASS SOLENOID VALVE............................................................................................ 445 ATT EPC VALVE ASSEMBLY...................................................................................................... 447 PILOT CIRCUIT ACCUMULATOR................................................................................................... 448 ATTACHMENT CIRCUIT ACCUMULATOR.............................................................................................. 449 SWING SYSTEM........................................................................................................................ 450 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 450 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 454 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 454 COMPONENT PARTS OF SWING SYSTEM................................................................................................. 458 SWING MOTOR................................................................................................................. 458 SWING MACHINERY............................................................................................................. 470 SWING CIRCLE................................................................................................................ 471 TRAVEL SYSTEM....................................................................................................................... 473 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 473 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 477 FUNCTION OF TRAVEL CONTROL SYSTEM........................................................................................... 477 COMPONENT PARTS OF TRAVEL SYSTEM................................................................................................ 479 TRAVEL MOTOR................................................................................................................ 479 FINAL DRIVE................................................................................................................. 491 TRAVEL PPC VALVE............................................................................................................ 493 CENTER SWIVEL JOINT......................................................................................................... 498 UNDERCARRIAGE AND FRAME............................................................................................................. 500 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................. 500 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 501 WORK EQUIPMENT...................................................................................................................... 502 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 502 FUNCTION OF WORK EQUIPMENT...................................................................................................... 503 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 504 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 504 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 505 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 505 CAB AND ITS ATTACHMENTS............................................................................................................. 506 ROPS CAB........................................................................................................................ 506 STRUCTURE OF ROPS CAB....................................................................................................... 506 FUNCTION OF ROPS CAB........................................................................................................ 506 CAB MOUNT....................................................................................................................... 507 STRUCTURE OF CAB MOUNT...................................................................................................... 507 FUNCTION OF CAB MOUNT....................................................................................................... 507 CAB TIPPING STOPPER............................................................................................................. 508 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 508 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 508 20 STANDARD VALUE TABLE................................................................................................................. 509 CONTENTS............................................................................................................................ 510 ABBREVIATION LIST................................................................................................................... 511 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 517 STANDARD VALUE TABLE FOR ENGINE: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0......................................... 517 STANDARD VALUE TABLE FOR MACHINE.................................................................................................... 522 STANDARD VALUE TABLE FOR MACHINE: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0........................................ 522 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE......................................................................... 535 STANDARD VALUE TABLE FOR ELECTRICAL................................................................................................. 539 STANDARD VALUE TABLE FOR ELECTRICAL............................................................................................. 539 30 TESTING AND ADJUSTING................................................................................................................ 549 CONTENTS............................................................................................................................ 550 ABBREVIATION LIST................................................................................................................... 553 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 559 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 559 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 566 ENGINE AND COOLING SYSTEM........................................................................................................... 568 TEST ENGINE SPEED............................................................................................................... 568 METHOD FOR TESTING ENGINE SPEED............................................................................................. 568 TEST BOOST PRESSURE............................................................................................................. 571 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR........................................................................ 571 METHOD FOR TESTING BOOST PRESSURE........................................................................................... 572 TEST EXHAUST GAS COLOR.......................................................................................................... 573 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................. 573 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER......................................................................... 574 TEST AND ADJUST VALVE CLEARANCE................................................................................................. 576 METHOD FOR TESTING VALVE CLEARANCE.......................................................................................... 576 METHOD FOR ADJUSTING VALVE CLEARANCE........................................................................................ 577 TEST COMPRESSION PRESSURE....................................................................................................... 579 METHOD FOR TESTING COMPRESSION PRESSURE..................................................................................... 579 TEST BLOWBY PRESSURE............................................................................................................ 584 METHOD FOR TESTING BLOWBY PRESSURE.......................................................................................... 584 TEST ENGINE OIL PRESSURE........................................................................................................ 586 METHOD FOR TESTING ENGINE OIL PRESSURE...................................................................................... 586 TEST EGR VALVE AND VGT OIL PRESSURE............................................................................................. 587 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................... 587 TEST FUEL PRESSURE.............................................................................................................. 589 METHOD FOR TESTING FUEL PRESSURE............................................................................................ 590 TEST FUEL DISCHARGE, RETURN AND LEAKAGE......................................................................................... 595 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE....................................................................... 596 BLEEDING AIR FROM FUEL SYSTEM................................................................................................... 602 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM.................................................................................... 602 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................... 603 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................. 603 HANDLE CYLINDER CUT-OUT MODE OPERATION.......................................................................................... 605 HANDLE NO-INJECTION CRANKING OPERATION.......................................................................................... 606 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 607 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT......................................................................... 607 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT........................................................................ 607 TEST FAN BELT AND ALTERNATOR BELT............................................................................................... 609 METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT............................................................................. 609 TEST AUTO-TENSIONER............................................................................................................. 610 METHOD FOR TESTING AUTO-TENSIONER........................................................................................... 610 REPLACING FAN BELT.............................................................................................................. 611 METHOD FOR REPLACING FAN BELT............................................................................................... 611 TEST COOLING FAN SPEED.......................................................................................................... 612 METHOD FOR TESTING COOLING FAN SPEED........................................................................................ 612 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................................. 613 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 613 TEST SCR RELATED FUNCTIONS...................................................................................................... 614 TEST AdBlue/DEF PUMP RAISED PRESSURE........................................................................................ 617 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR.............................................................................. 620 TEST AdBlue/DEF LINE HEATER RELAY 1......................................................................................... 624 TEST AdBlue/DEF LINE HEATER RELAY 2......................................................................................... 627 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................... 629 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................... 632 TEST DENITRATION EFFICIENCY OF SCR.......................................................................................... 635 CLEAN AdBlue/DEF TANK........................................................................................................... 639 METHOD FOR CLEANING AdBlue/DEF TANK......................................................................................... 639 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................................................... 643 METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................................. 643 POWER TRAIN......................................................................................................................... 645 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................. 645 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE........................................................................... 645 UNDERCARRIAGE AND FRAME............................................................................................................. 646 TEST AND ADJUST TRACK TENSION................................................................................................... 646 METHOD FOR TESTING TRACK TENSION............................................................................................ 646 METHOD FOR ADJUSTING TRACK TENSION.......................................................................................... 646 HYDRAULIC SYSTEM.................................................................................................................... 648 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 648 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK................................................................. 648 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT....................................................... 648 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...................................................... 654 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................... 655 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................. 661 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 664 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 664 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT......................................................................... 666 TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................................. 666 TEST PC-EPC VALVE OUTLET PRESSURE........................................................................................... 667 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT................................................................ 668 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT......................................................................... 670 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR.............................................................. 670 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL................................................................. 671 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................... 674 METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE............................................................................. 675 METHOD FOR ADJUSTING LS VALVE............................................................................................... 676 TEST OUTLET PRESSURE OF SOLENOID VALVE.......................................................................................... 677 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE........................................................................ 677 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 678 TEST PPC VALVE OUTLET PRESSURE.................................................................................................. 681 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE................................................................................ 681 TEST ATTACHMENT CIRCUIT OIL PRESSURE............................................................................................ 683 METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE.......................................................................... 683 ADJUST WORK EQUIPMENT AND SWING PPC VALVES...................................................................................... 685 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............................................................ 685 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE............................................................. 686 TEST PUMP SWASH PLATE SENSOR.................................................................................................... 688 METHOD FOR TESTING PUMP SWASH PLATE SENSOR.................................................................................. 688 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................................ 689 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER................................... 689 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER........................................................ 689 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE........................................................... 690 TEST OIL LEAKAGE................................................................................................................ 691 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER........................................................................... 691 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER............................................................................ 691 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER......................................................................... 692 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR............................................................................. 693 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR............................................................................ 693 BLEED AIR FROM HYDRAULIC CIRCUIT................................................................................................ 694 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.............................................................................. 696 CAB AND ITS ATTACHMENTS............................................................................................................. 698 TEST CAB TIPPING STOPPER........................................................................................................ 698 METHOD FOR TESTING CAB TIPPING STOPPER...................................................................................... 698 METHOD FOR ADJUSTING MIRRORS.................................................................................................... 699 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)....................................................................... 699 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)................................................... 700 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210-11E0, PC210LC-11E0)........................................... 701 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11E0, PC230NHD-11E0)....................................... 702 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210-11E0, PC210LC-11E0)....................... 703 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11E0, PC230NHD-11E0)................... 704 PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)....................................................................... 705 ELECTRICAL SYSTEM................................................................................................................... 707 SETTING AND OPERATION OF MACHINE MONITOR........................................................................................ 707 OPERATOR MODE............................................................................................................... 710 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 711 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 711 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................... 712 CHECKING FUNCTION OF SERVICE METER.......................................................................................... 712 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD................................................................... 712 SERVICE MODE................................................................................................................ 715 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...................................................................... 717 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...................................................................... 724 ABNORMALITY RECORD MENU..................................................................................................... 734 METHOD FOR CONFIRMING MAINTENANCE RECORD.................................................................................... 739 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................... 740 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................. 744 DEFAULT MENU................................................................................................................ 745 DIAGNOSTIC TESTS MENU....................................................................................................... 757 ADJUSTMENT MENU............................................................................................................. 766 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................................. 801 KOMTRAX SETTINGS MENU....................................................................................................... 802 METHOD FOR DISPLAYING SERVICE MESSAGE....................................................................................... 804 METHOD FOR STARTING UP KOMTRAX SYSTEM....................................................................................... 805 ADJUST REARVIEW CAMERA ANGLE................................................................................................ 810 ADJUST KomVision CAMERA ANGLE................................................................................................... 813 METHOD FOR ADJUSTING KomVision CAMERA ANGLE................................................................................. 814 ADJUST KomVision RELATED ITEMS.................................................................................................. 818 SETTING OF KomVision (MAIN SETTING)......................................................................................... 818 SETTING OF KomVision (CAMERA SETTING)....................................................................................... 820 SETTING OF KomVision (CAMERA CALIBRATION)................................................................................... 822 KomVision screen - Check 12 m visibility.................................................................................... 835 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 838 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 839 TEST DIODES..................................................................................................................... 840 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 840 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 840 Pm CLINIC........................................................................................................................... 841 Pm CLINIC SERVICE............................................................................................................... 841 Pm CLINIC CHECK SHEET....................................................................................................... 845 40 TROUBLESHOOTING...................................................................................................................... 857 CONTENTS............................................................................................................................ 858 ABBREVIATION LIST................................................................................................................... 869 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 875 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 875 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 876 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 888 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 890 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 892 WALK-AROUND CHECK........................................................................................................... 892 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 894 CHECK FUEL LEVEL AND TYPE................................................................................................... 894 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 894 CHECK FUEL PREFILTER........................................................................................................ 895 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 895 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................................... 896 CHECK MAIN FILTER........................................................................................................... 897 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 899 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 900 CHECK CLOGGING OF AIR CLEANER............................................................................................... 900 OUTER ELEMENT - CLEAN....................................................................................................... 901 ELEMENTS - REPLACE.......................................................................................................... 903 CHECK HYDRAULIC OIL LEVEL................................................................................................... 904 CHECK HYDRAULIC OIL STRAINER................................................................................................ 905 CHECK HYDRAULIC FILTER...................................................................................................... 906 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 907 CHECK OIL LEVEL IN DAMPER CASE.............................................................................................. 908 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 908 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 909 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 909 ELECTRICAL EQUIPMENT - CHECK METHOD......................................................................................... 909 AUTOMATIC GREASE SYSTEM......................................................................................................... 917 FINDING MALFUNCTIONS........................................................................................................ 917 MALFUNCTION FINDING PROCEDURES.............................................................................................. 921 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM................................................................................... 923 PROCEDURE FOR TESTING AND TROUBLESHOOTING....................................................................................... 936 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................. 939 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................................. 943 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................. 945 CONNECTOR LIST AND LAYOUT....................................................................................................... 948 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 961 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.........................................................................................1001 FUSE LOCATION TABLE.............................................................................................................1007 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).....................................................................1010 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).....................................1014 FAILURE CODES TABLE.............................................................................................................1016 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...................................................................................1034 FAILURE CODE [879AKA]...........................................................................................................1034 FAILURE CODE [879AKB]...........................................................................................................1035 FAILURE CODE [879BKA]...........................................................................................................1036 FAILURE CODE [879BKB]...........................................................................................................1038 FAILURE CODE [879CKA]...........................................................................................................1040 FAILURE CODE [879CKB]...........................................................................................................1041 FAILURE CODE [879DKZ]...........................................................................................................1042 FAILURE CODE [879EMC]...........................................................................................................1044 FAILURE CODE [879FMC]...........................................................................................................1045 FAILURE CODE [879GKX]...........................................................................................................1046 FAILURE CODE [989L00]...........................................................................................................1048 FAILURE CODE [989M00]...........................................................................................................1049 FAILURE CODE [989N00]...........................................................................................................1050 FAILURE CODE [A1U0N3]...........................................................................................................1051 FAILURE CODE [A1U0N4]...........................................................................................................1053 FAILURE CODE [A900FR]...........................................................................................................1055 FAILURE CODE [A900N6]...........................................................................................................1056 FAILURE CODE [A900NY]...........................................................................................................1057 FAILURE CODE [AA10NX]...........................................................................................................1058 FAILURE CODE [AB00KE]...........................................................................................................1060 FAILURE CODE [AQ10N3]...........................................................................................................1063 FAILURE CODE [AS00N3]...........................................................................................................1065 FAILURE CODE [AS00R2]...........................................................................................................1067 FAILURE CODE [AS00R3]...........................................................................................................1068 FAILURE CODE [AS00R4]...........................................................................................................1069 FAILURE CODE [AS00R5]...........................................................................................................1070 FAILURE CODE [AS00R6]...........................................................................................................1071 FAILURE CODE [AS00ZK]...........................................................................................................1072 FAILURE CODE [AS10KM]...........................................................................................................1073 FAILURE CODE [AS10NR]...........................................................................................................1074 FAILURE CODE [AS10NT]...........................................................................................................1075 FAILURE CODE [B@BAZG]...........................................................................................................1076 FAILURE CODE [B@BAZK]...........................................................................................................1077 FAILURE CODE [B@BCNS]...........................................................................................................1079 FAILURE CODE [B@BCQA]...........................................................................................................1080 FAILURE CODE [B@BCZK]...........................................................................................................1082 FAILURE CODE [B@HANS]...........................................................................................................1084 FAILURE CODE [CA115]............................................................................................................1085 FAILURE CODE [CA122]............................................................................................................1086 FAILURE CODE [CA123]............................................................................................................1088 FAILURE CODE [CA131]............................................................................................................1090 FAILURE CODE [CA132]............................................................................................................1092 FAILURE CODE [CA144]............................................................................................................1094 FAILURE CODE [CA145]............................................................................................................1096 FAILURE CODE [CA153]............................................................................................................1098 FAILURE CODE [CA154]............................................................................................................1101 FAILURE CODE [CA187]............................................................................................................1103 FAILURE CODE [CA221]............................................................................................................1105 FAILURE CODE [CA222]............................................................................................................1107 FAILURE CODE [CA227]............................................................................................................1109 FAILURE CODE [CA234]............................................................................................................1110 FAILURE CODE [CA238]............................................................................................................1111 FAILURE CODE [CA239]............................................................................................................1113 FAILURE CODE [CA249]............................................................................................................1115 FAILURE CODE [CA256]............................................................................................................1117 FAILURE CODE [CA271]............................................................................................................1119 FAILURE CODE [CA272]............................................................................................................1121 FAILURE CODE [CA322]............................................................................................................1123 FAILURE CODE [CA323]............................................................................................................1125 FAILURE CODE [CA324]............................................................................................................1127 FAILURE CODE [CA325]............................................................................................................1129 FAILURE CODE [CA331]............................................................................................................1131 FAILURE CODE [CA332]............................................................................................................1133 FAILURE CODE [CA343]............................................................................................................1135 FAILURE CODE [CA351]............................................................................................................1136 FAILURE CODE [CA352]............................................................................................................1137 FAILURE CODE [CA356]............................................................................................................1140 FAILURE CODE [CA357]............................................................................................................1142 FAILURE CODE [CA386]............................................................................................................1144 FAILURE CODE [CA428]............................................................................................................1145 FAILURE CODE [CA429]............................................................................................................1147 FAILURE CODE [CA435]............................................................................................................1149 FAILURE CODE [CA441]............................................................................................................1151 FAILURE CODE [CA442]............................................................................................................1153 FAILURE CODE [CA449]............................................................................................................1154 FAILURE CODE [CA451]............................................................................................................1155 FAILURE CODE [CA452]............................................................................................................1157 FAILURE CODE [CA488]............................................................................................................1159 FAILURE CODE [CA515]............................................................................................................1160 FAILURE CODE [CA516]............................................................................................................1162 FAILURE CODE [CA553]............................................................................................................1164 FAILURE CODE [CA555]............................................................................................................1165 FAILURE CODE [CA556]............................................................................................................1166 FAILURE CODE [CA559]............................................................................................................1167 FAILURE CODE [CA595]............................................................................................................1170 FAILURE CODE [CA687]............................................................................................................1171 FAILURE CODE [CA689]............................................................................................................1173 FAILURE CODE [CA691]............................................................................................................1176 FAILURE CODE [CA692]............................................................................................................1178 FAILURE CODE [CA697]............................................................................................................1180 FAILURE CODE [CA698]............................................................................................................1181 FAILURE CODE [CA731]............................................................................................................1182 FAILURE CODE [CA778]............................................................................................................1184 FAILURE CODE [CA1117]...........................................................................................................1189 FAILURE CODE [CA1664]...........................................................................................................1190 FAILURE CODE [CA1669]...........................................................................................................1192 FAILURE CODE [CA1673]...........................................................................................................1193 FAILURE CODE [CA1677]...........................................................................................................1194 FAILURE CODE [CA1678]...........................................................................................................1195 FAILURE CODE [CA1682]...........................................................................................................1196 FAILURE CODE [CA1683]...........................................................................................................1198 FAILURE CODE [CA1684]...........................................................................................................1200 FAILURE CODE [CA1686]...........................................................................................................1202 FAILURE CODE [CA1691]...........................................................................................................1203 FAILURE CODE [CA1694]...........................................................................................................1206 FAILURE CODE [CA1695]...........................................................................................................1209 FAILURE CODE [CA1696]...........................................................................................................1210 FAILURE CODE [CA1712]...........................................................................................................1212 FAILURE CODE [CA1713]...........................................................................................................1215 FAILURE CODE [CA1714]...........................................................................................................1217 FAILURE CODE [CA1715]...........................................................................................................1218 FAILURE CODE [CA1776]...........................................................................................................1219 FAILURE CODE [CA1777]...........................................................................................................1222 FAILURE CODE [CA1843]...........................................................................................................1225 FAILURE CODE [CA1844]...........................................................................................................1227 FAILURE CODE [CA1879]...........................................................................................................1230 FAILURE CODE [CA1881]...........................................................................................................1232 FAILURE CODE [CA1883]...........................................................................................................1234 FAILURE CODE [CA1885]...........................................................................................................1237 FAILURE CODE [CA1887]...........................................................................................................1239 FAILURE CODE [CA1921]...........................................................................................................1241 FAILURE CODE [CA1922]...........................................................................................................1244 FAILURE CODE [CA1942]...........................................................................................................1249 FAILURE CODE [CA1993]...........................................................................................................1250 FAILURE CODE [CA2185]...........................................................................................................1253 FAILURE CODE [CA2186]...........................................................................................................1254 FAILURE CODE [CA2249]...........................................................................................................1256 FAILURE CODE [CA2271]...........................................................................................................1257 FAILURE CODE [CA2272]...........................................................................................................1260 FAILURE CODE [CA2288]...........................................................................................................1263 FAILURE CODE [CA2311]...........................................................................................................1264 FAILURE CODE [CA2349]...........................................................................................................1265 FAILURE CODE [CA2353]...........................................................................................................1268 FAILURE CODE [CA2357]...........................................................................................................1270 FAILURE CODE [CA2381]...........................................................................................................1271 FAILURE CODE [CA2382]...........................................................................................................1274 FAILURE CODE [CA2383]...........................................................................................................1277 FAILURE CODE [CA2386]...........................................................................................................1280 FAILURE CODE [CA2387]...........................................................................................................1282 FAILURE CODE [CA2555]...........................................................................................................1283 FAILURE CODE [CA2556]...........................................................................................................1286 FAILURE CODE [CA2637]...........................................................................................................1289 FAILURE CODE [CA2639]...........................................................................................................1291 FAILURE CODE [CA2771]...........................................................................................................1294 FAILURE CODE [CA2777]...........................................................................................................1300 FAILURE CODE [CA2976]...........................................................................................................1303 FAILURE CODE [CA3133]...........................................................................................................1305 FAILURE CODE [CA3134]...........................................................................................................1308 FAILURE CODE [CA3135]...........................................................................................................1310 FAILURE CODE [CA3142]...........................................................................................................1313 FAILURE CODE [CA3143]...........................................................................................................1314 FAILURE CODE [CA3144]...........................................................................................................1315 FAILURE CODE [CA3146]...........................................................................................................1317 FAILURE CODE [CA3147]...........................................................................................................1318 FAILURE CODE [CA3148]...........................................................................................................1319 FAILURE CODE [CA3151]...........................................................................................................1321 FAILURE CODE [CA3165]...........................................................................................................1327 FAILURE CODE [CA3229]...........................................................................................................1329 FAILURE CODE [CA3231]...........................................................................................................1331 FAILURE CODE [CA3232]...........................................................................................................1333 FAILURE CODE [CA3235]...........................................................................................................1337 FAILURE CODE [CA3239]...........................................................................................................1339 FAILURE CODE [CA3241]...........................................................................................................1342 FAILURE CODE [CA3242]...........................................................................................................1345 FAILURE CODE [CA3251]...........................................................................................................1348 FAILURE CODE [CA3253]...........................................................................................................1350 FAILURE CODE [CA3254]...........................................................................................................1353 FAILURE CODE [CA3255]...........................................................................................................1356 FAILURE CODE [CA3256]...........................................................................................................1360 FAILURE CODE [CA3311]...........................................................................................................1362 FAILURE CODE [CA3312]...........................................................................................................1364 FAILURE CODE [CA3313]...........................................................................................................1367 FAILURE CODE [CA3314]...........................................................................................................1368 FAILURE CODE [CA3315]...........................................................................................................1369 FAILURE CODE [CA3316]...........................................................................................................1371 FAILURE CODE [CA3317]...........................................................................................................1372 FAILURE CODE [CA3318]...........................................................................................................1373 FAILURE CODE [CA3319]...........................................................................................................1375 FAILURE CODE [CA3321]...........................................................................................................1376 FAILURE CODE [CA3322]...........................................................................................................1378 FAILURE CODE [CA3419]...........................................................................................................1380 FAILURE CODE [CA3421]...........................................................................................................1382 FAILURE CODE [CA3497]...........................................................................................................1384 FAILURE CODE [CA3498]...........................................................................................................1385 FAILURE CODE [CA3543]...........................................................................................................1386 FAILURE CODE [CA3545]...........................................................................................................1393 FAILURE CODE [CA3547]...........................................................................................................1395 FAILURE CODE [CA3558]...........................................................................................................1396 FAILURE CODE [CA3559]...........................................................................................................1398 FAILURE CODE [CA3562]...........................................................................................................1400 FAILURE CODE [CA3563]...........................................................................................................1402 FAILURE CODE [CA3567]...........................................................................................................1405 FAILURE CODE [CA3568]...........................................................................................................1408 FAILURE CODE [CA3571]...........................................................................................................1412 FAILURE CODE [CA3572]...........................................................................................................1414 FAILURE CODE [CA3574]...........................................................................................................1416 FAILURE CODE [CA3575]...........................................................................................................1418 FAILURE CODE [CA3577]...........................................................................................................1420 FAILURE CODE [CA3578]...........................................................................................................1422 FAILURE CODE [CA3582]...........................................................................................................1424 FAILURE CODE [CA3583]...........................................................................................................1430 FAILURE CODE [CA3596]...........................................................................................................1432 FAILURE CODE [CA3649]...........................................................................................................1434 FAILURE CODE [CA3681]...........................................................................................................1436 FAILURE CODE [CA3682]...........................................................................................................1441 FAILURE CODE [CA3713]...........................................................................................................1447 FAILURE CODE [CA3717]...........................................................................................................1450 FAILURE CODE [CA3718]...........................................................................................................1451 FAILURE CODE [CA3725]...........................................................................................................1452 FAILURE CODE [CA3741]...........................................................................................................1455 FAILURE CODE [CA3748]...........................................................................................................1456 FAILURE CODE [CA3751]...........................................................................................................1458 FAILURE CODE [CA3755]...........................................................................................................1460 FAILURE CODE [CA3866]...........................................................................................................1462 FAILURE CODE [CA3867]...........................................................................................................1466 FAILURE CODE [CA3868]...........................................................................................................1469 FAILURE CODE [CA3899]...........................................................................................................1473 FAILURE CODE [CA3911]...........................................................................................................1475 FAILURE CODE [CA3912]...........................................................................................................1479 FAILURE CODE [CA3932]...........................................................................................................1481 FAILURE CODE [CA3933]...........................................................................................................1483 FAILURE CODE [CA3934]...........................................................................................................1485 FAILURE CODE [CA3935]...........................................................................................................1488 FAILURE CODE [CA3936]...........................................................................................................1490 FAILURE CODE [CA4151]...........................................................................................................1492 FAILURE CODE [CA4152]...........................................................................................................1496 FAILURE CODE [CA4155]...........................................................................................................1500 FAILURE CODE [CA4156]...........................................................................................................1502 FAILURE CODE [CA4157]...........................................................................................................1504 FAILURE CODE [CA4158]...........................................................................................................1506 FAILURE CODE [CA4159]...........................................................................................................1507 FAILURE CODE [CA4161]...........................................................................................................1508 FAILURE CODE [CA4162]...........................................................................................................1511 FAILURE CODE [CA4163]...........................................................................................................1514 FAILURE CODE [CA4164]...........................................................................................................1515 FAILURE CODE [CA4166]...........................................................................................................1517 FAILURE CODE [CA4168]...........................................................................................................1518 FAILURE CODE [CA4169]...........................................................................................................1521 FAILURE CODE [CA4171]...........................................................................................................1523 FAILURE CODE [CA4249]...........................................................................................................1526 FAILURE CODE [CA4251]...........................................................................................................1528 FAILURE CODE [CA4259]...........................................................................................................1530 FAILURE CODE [CA4261]...........................................................................................................1533 FAILURE CODE [CA4277]...........................................................................................................1536 FAILURE CODE [CA4281]...........................................................................................................1539 FAILURE CODE [CA4459]...........................................................................................................1542 FAILURE CODE [CA4461]...........................................................................................................1545 FAILURE CODE [CA4658]...........................................................................................................1548 FAILURE CODE [CA4731]...........................................................................................................1552 FAILURE CODE [CA4732]...........................................................................................................1553 FAILURE CODE [CA4739]...........................................................................................................1554 FAILURE CODE [CA4768]...........................................................................................................1555 FAILURE CODE [CA4769]...........................................................................................................1557 FAILURE CODE [CA4842]...........................................................................................................1560 FAILURE CODE [CA4952]...........................................................................................................1564 FAILURE CODE [CA5115]...........................................................................................................1566 FAILURE CODE [CA5179]...........................................................................................................1569 FAILURE CODE [CA5181]...........................................................................................................1571 FAILURE CODE [CA5383]...........................................................................................................1573 FAILURE CODE [D110KB]...........................................................................................................1575 FAILURE CODE [D19JKZ]...........................................................................................................1577 FAILURE CODE [D811MC]...........................................................................................................1580 FAILURE CODE [D862KA]...........................................................................................................1581 FAILURE CODE [D8ALKA]...........................................................................................................1583 FAILURE CODE [D8ALKB]...........................................................................................................1586 FAILURE CODE [D8AQKR]...........................................................................................................1588 FAILURE CODE [D8G1KT]...........................................................................................................1595 FAILURE CODE [D8G6KT]...........................................................................................................1596 FAILURE CODE [DA20MC]...........................................................................................................1597 FAILURE CODE [DA22KK]...........................................................................................................1598 FAILURE CODE [DA25KP]...........................................................................................................1601 FAILURE CODE [DA26KP]...........................................................................................................1604 FAILURE CODE [DA29KQ]...........................................................................................................1607 FAILURE CODE [DA2LKA]...........................................................................................................1609 FAILURE CODE [DA2LKB]...........................................................................................................1612 FAILURE CODE [DA2QKR]...........................................................................................................1614 FAILURE CODE [DA2RKR]...........................................................................................................1623 FAILURE CODE [DAF0KM]...........................................................................................................1624 FAILURE CODE [DAF0MB]...........................................................................................................1625 FAILURE CODE [DAF0MC]...........................................................................................................1626 FAILURE CODE [DAF8KB]...........................................................................................................1627 FAILURE CODE [DAF9KQ]...........................................................................................................1629 FAILURE CODE [DAFGMC]...........................................................................................................1630 FAILURE CODE [DAFLKA]...........................................................................................................1631 FAILURE CODE [DAFLKB]...........................................................................................................1634 FAILURE CODE [DAFQKR]...........................................................................................................1636 FAILURE CODE [DAZ9KQ]...........................................................................................................1644 FAILURE CODE [DAZQKR]...........................................................................................................1645 FAILURE CODE [DB2QKR]...........................................................................................................1652 FAILURE CODE [DBP0KM]...........................................................................................................1660 FAILURE CODE [DBP0KT]...........................................................................................................1661 FAILURE CODE [DB2RKR]...........................................................................................................1662 FAILURE CODE [DBP5KB]...........................................................................................................1667 FAILURE CODE [DBP5KY]...........................................................................................................1670 FAILURE CODE [DBPQKR]...........................................................................................................1673 FAILURE CODE [DDNRKA]...........................................................................................................1681 FAILURE CODE [DDNRKY]...........................................................................................................1683 FAILURE CODE [DDNS00]...........................................................................................................1685 FAILURE CODE [DFB1KZ]...........................................................................................................1687 FAILURE CODE [DFB2KZ]...........................................................................................................1689 FAILURE CODE [DFB3L8]...........................................................................................................1691 FAILURE CODE [DFB4L8]...........................................................................................................1693 FAILURE CODE [DFB5KZ]...........................................................................................................1695 FAILURE CODE [DFB6KZ]...........................................................................................................1697 FAILURE CODE [DGH2KA]...........................................................................................................1699 FAILURE CODE [DGH2KB]...........................................................................................................1701 FAILURE CODE [DHA4KA]...........................................................................................................1703 FAILURE CODE [DHAAMA]...........................................................................................................1705 FAILURE CODE [DHACMA]...........................................................................................................1707 FAILURE CODE [DHPAMA]...........................................................................................................1709 FAILURE CODE [DHPBMA]...........................................................................................................1712 FAILURE CODE [DHS3MA]...........................................................................................................1715 FAILURE CODE [DHS4MA]...........................................................................................................1718 FAILURE CODE [DHS8MA]...........................................................................................................1721 FAILURE CODE [DHS9MA]...........................................................................................................1724 FAILURE CODE [DHSAMA]...........................................................................................................1727 FAILURE CODE [DHSBMA]...........................................................................................................1730 FAILURE CODE [DHSCMA]...........................................................................................................1733 FAILURE CODE [DHSDMA]...........................................................................................................1736 FAILURE CODE [DHSFMA]...........................................................................................................1739 FAILURE CODE [DHSGMA]...........................................................................................................1742 FAILURE CODE [DHSHMA]...........................................................................................................1745 FAILURE CODE [DHSJMA]...........................................................................................................1748 FAILURE CODE [DHX1MA]...........................................................................................................1751 FAILURE CODE [DHZAMA]...........................................................................................................1754 FAILURE CODE [DHZCL8]...........................................................................................................1758 FAILURE CODE [DKR0MA]...........................................................................................................1759 FAILURE CODE [DKR1MA]...........................................................................................................1762 FAILURE CODE [DKULKA]...........................................................................................................1765 FAILURE CODE [DKULKB]...........................................................................................................1767 FAILURE CODE [DKULKY]...........................................................................................................1769 FAILURE CODE [DLM5KA]...........................................................................................................1771 FAILURE CODE [DLM5MB]...........................................................................................................1773 FAILURE CODE [DR10KA]...........................................................................................................1775 FAILURE CODE [DR12KA]...........................................................................................................1778 FAILURE CODE [DR20KA]...........................................................................................................1780 FAILURE CODE [DR21KX]...........................................................................................................1782 FAILURE CODE [DR30KA]...........................................................................................................1784 FAILURE CODE [DR31KX]...........................................................................................................1786 FAILURE CODE [DR40KA]...........................................................................................................1788 FAILURE CODE [DUMBKA]...........................................................................................................1790 FAILURE CODE [DUMBKB]...........................................................................................................1793 FAILURE CODE [DV00KA]...........................................................................................................1795 FAILURE CODE [DV00KB]...........................................................................................................1796 FAILURE CODE [DV20KB]...........................................................................................................1797 FAILURE CODE [DW43KA]...........................................................................................................1799 FAILURE CODE [DW43KB]...........................................................................................................1801 FAILURE CODE [DW43KY]...........................................................................................................1803 FAILURE CODE [DW45KA]...........................................................................................................1805 FAILURE CODE [DW45KB]...........................................................................................................1808 FAILURE CODE [DW45KY]...........................................................................................................1811 FAILURE CODE [DW4CKY]...........................................................................................................1813 FAILURE CODE [DW91KA]...........................................................................................................1815 FAILURE CODE [DW91KB]...........................................................................................................1817 FAILURE CODE [DW91KY]...........................................................................................................1819 FAILURE CODE [DWA2KA]...........................................................................................................1821 FAILURE CODE [DWA2KB]...........................................................................................................1823 FAILURE CODE [DWA2KY]...........................................................................................................1825 FAILURE CODE [DWK0KA]...........................................................................................................1827 FAILURE CODE [DWK0KB]...........................................................................................................1829 FAILURE CODE [DWK0KY]...........................................................................................................1831 FAILURE CODE [DWK2KA]...........................................................................................................1833 FAILURE CODE [DWK2KB]...........................................................................................................1835 FAILURE CODE [DWK2KY]...........................................................................................................1837 FAILURE CODE [DWK8KA]...........................................................................................................1839 FAILURE CODE [DWK8KB]...........................................................................................................1841 FAILURE CODE [DWK8KY]...........................................................................................................1843 FAILURE CODE [DWN5KA]...........................................................................................................1845 FAILURE CODE [DWN5KB]...........................................................................................................1847 FAILURE CODE [DWN5KY]...........................................................................................................1849 FAILURE CODE [DWPUKA]...........................................................................................................1851 FAILURE CODE [DWPUKB]...........................................................................................................1853 FAILURE CODE [DWPUKY]...........................................................................................................1855 FAILURE CODE [DXA8KA]...........................................................................................................1857 FAILURE CODE [DXA8KB]...........................................................................................................1859 FAILURE CODE [DXA9KA]...........................................................................................................1861 FAILURE CODE [DXA9KB]...........................................................................................................1863 FAILURE CODE [DXE0KA]...........................................................................................................1865 FAILURE CODE [DXE0KB]...........................................................................................................1866 FAILURE CODE [DXE4KA]...........................................................................................................1868 FAILURE CODE [DXE4KB]...........................................................................................................1870 FAILURE CODE [DXE4KY]...........................................................................................................1872 FAILURE CODE [DXE5KA]...........................................................................................................1874 FAILURE CODE [DXE5KB]...........................................................................................................1876 FAILURE CODE [DXE6KA]...........................................................................................................1878 FAILURE CODE [DXE6KB]...........................................................................................................1880 FAILURE CODE [DXE7KA]...........................................................................................................1882 FAILURE CODE [DXE7KB]...........................................................................................................1884 FAILURE CODE [DXE7KY]...........................................................................................................1886 FAILURE CODE [DXE8KA]...........................................................................................................1888 FAILURE CODE [DXE8KB]...........................................................................................................1890 FAILURE CODE [DXE8KY]...........................................................................................................1892 FAILURE CODE [DXE9KA]...........................................................................................................1894 FAILURE CODE [DXE9KB]...........................................................................................................1896 FAILURE CODE [DXE9KY]...........................................................................................................1898 FAILURE CODE [DXEAKA]...........................................................................................................1900 FAILURE CODE [DXEAKB]...........................................................................................................1902 FAILURE CODE [DXEAKY]...........................................................................................................1904 FAILURE CODE [DXEKKA]...........................................................................................................1906 FAILURE CODE [DXEKKB]...........................................................................................................1908 FAILURE CODE [DXEKKY]...........................................................................................................1910 FAILURE CODE [DXELKA]...........................................................................................................1912 FAILURE CODE [DXELKB]...........................................................................................................1914 FAILURE CODE [DXELKY]...........................................................................................................1916 FAILURE CODE [DY20KA]...........................................................................................................1918 FAILURE CODE [DY20MA]...........................................................................................................1920 FAILURE CODE [DY2CKB]...........................................................................................................1922 FAILURE CODE [DY2DKB]...........................................................................................................1925 FAILURE CODE [DY2EKB]...........................................................................................................1927 FAILURE CODE [F313KA]...........................................................................................................1929 FAILURE CODE [F313KB]...........................................................................................................1931 FAILURE CODE [F318KB]...........................................................................................................1934 FAILURE CODE [F318KY]...........................................................................................................1937 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1939 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................1939 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................1945 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................1948 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................1950 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................1952 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........1955 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....1956 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................1957 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................1958 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................1959 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1960 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1961 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................................1962 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................1963 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................1964 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................1965 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................1966 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................1968 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................1969 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................1970 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................1971 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................1973 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................1974 E-24 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................1975 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................1976 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................1977 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................1978 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................1979 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................1980 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................1981 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................1982 E-32 ALARM BUZZER CANNOT BE CANCELED............................................................................................1984 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................1985 E-34 SERVICE MODE CANNOT BE SELECTED............................................................................................1986 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................1987 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................1990 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................1992 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................1995 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................1997 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................2000 E-41 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................2001 E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................2003 E-43 HORN DOES NOT SOUND........................................................................................................2004 E-44 HORN DOES NOT STOP SOUNDING................................................................................................2007 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................2009 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................2010 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................2012 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................2013 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................2014 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................2015 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................2016 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................2017 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................2018 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................2019 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................2020 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................2021 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.............................................................................2023 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................2024 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................2025 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).........................................................................2025 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS................................................................................2026 FAILURE MODE AND CAUSE TABLE....................................................................................................2028 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK............................................................................2037 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...................................................................2038 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR................................................................................2041 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................2042 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................2043 H-6 SPEED OR POWER OF BOOM IS LOW...............................................................................................2045 H-7 ARM SPEED OR POWER IS LOW...................................................................................................2049 H-8 BUCKET SPEED OR POWER IS LOW................................................................................................2054 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION............................................................................2057 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................2058 H-11 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................2060 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................2062 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................................2063 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................2064 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................2065 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................................2066 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................2067 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................................2068 H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY......................................................2069 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW....................................................2070 H-21 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................2071 H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................................2073 H-23 TRAVEL SPEED IS LOW........................................................................................................2076 H-24 ONE OF TRACKS DOES NOT RUN.................................................................................................2078 H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................................2079 H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................................2080 H-27 SWINGS ONLY IN ONE DIRECTION...............................................................................................2081 H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................................2082 H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................................2083 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................................2084 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......................2085 H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................................2086 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................................2087 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................2088 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................2089 H-1 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)......................................................................2090 H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN.....................................................................................2091 H-38 Quick coupler cylinder will not extend.....................................................................................2092 H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound).........................................................2094 H-40 Buzzer does not sound (but quick coupler cylinder doesretract).............................................................2096 H-41 Quick coupler cylinder extends and retracts slowly.........................................................................2098 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................2099 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................2099 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................2100 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................2101 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................2102 S-4 ENGINE STARTABILITY IS POOR.................................................................................................2104 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................2106 S-6 ENGINE STOPS DURING OPERATION...............................................................................................2108 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................2110 S-8 ENGINE LACKS POWER..........................................................................................................2111 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................2113 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................2115 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................2116 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................2117 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................2118 S-14 OIL PRESSURE DROPS.........................................................................................................2119 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................2121 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................2122 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................2123 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................2124 S-19 VIBRATION IS EXCESSIVE.....................................................................................................2125 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................2126 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................2127 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................2129 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................2130 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................2131 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................2133 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................2134 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................2135 CONTENTS............................................................................................................................2136 ABBREVIATION LIST...................................................................................................................2141 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................2147 HOW TO READ THIS MANUAL.........................................................................................................2147 COATING MATERIALS LIST..........................................................................................................2149 SPECIAL TOOLS LIST..............................................................................................................2154 SKETCHES OF SPECIAL TOOLS.......................................................................................................2166 ENGINE AND COOLING SYSTEM...........................................................................................................2172 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................2172 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................2172 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................2175 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................2178 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................2178 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................2183 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................2191 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................2192 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................2201 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................2217 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................2217 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................2218 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................2220 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................2220 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................2224 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................2229 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................2229 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................2230 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................2233 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................2233 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................2235 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................2238 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................2238 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................2240 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................2243 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................2243 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................2246 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................2249 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................2249 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................2251 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY..........................................................................................2253 REMOVE FAN CLUTCH ASSEMBLY..................................................................................................2253 INSTALL FAN CLUTCH ASSEMBLY.................................................................................................2258 REMOVE AND INSTALL FAN..........................................................................................................2262 METHOD FOR INSTALLING FAN...................................................................................................2262 METHOD FOR REMOVING FAN.....................................................................................................2262 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................2263 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...........................................................................2263 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY.........................................................................2272 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2284 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2284 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2287 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2291 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2291 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2292 REMOVE AND INSTALL FUEL COOLER ASSEMBLY.........................................................................................2295 METHOD FOR REMOVING FUEL COOLER ASSEMBLY....................................................................................2295 METHOD FOR INSTALLING FUEL COOLER ASSEMBLY..................................................................................2295 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2297 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2297 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2299 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2304 METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210-11E0, PC210LC-11E0)...........................................................2304 METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210NLC-11E0, PC230NHD-11E0).......................................................2308 METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210-11E0, PC210LC-11E0).........................................................2312 METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210NLC-11E0, PC230NHD-11E0).....................................................2316 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2320 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2320 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2326 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2332 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2332 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2338 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2343 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2343 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2343 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2350 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...................................................................................2350 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2350 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2351 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2358 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................................................................................2358 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER..............................................................................2358 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER...........................................................................2359 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER......................................................................2359 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER....................................................................2361 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2364 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2364 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2366 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2368 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2369 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2372 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2377 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2377 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2379 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2381 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2381 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2387 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...................................................................................2393 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (PC210-11E0, PC210LC-11E0)...................................................2393 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (FOR PC210NLC-11E0, PC230NHD-11E0)...........................................2400 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210-11E0, PC210LC-11E0).................................................2408 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210NLC-11E0, PC230NHD-11E0).............................................2416 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2424 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2424 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2426 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2431 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2431 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2437 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2443 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2443 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2446 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2449 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2449 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2452 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2455 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2455 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2463 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2469 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2469 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2470 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2472 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2472 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2474 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2477 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2477 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2478 POWER TRAIN.........................................................................................................................2479 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2479 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2479 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2480 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2482 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2482 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2486 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................2495 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................2495 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................2497 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2501 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2501 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2505 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2512 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2512 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2512 UNDERCARRIAGE AND FRAME.............................................................................................................2514 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2514 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2514 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2516 REMOVE AND INSTALL SPROCKET.....................................................................................................2519 METHOD FOR REMOVING SPROCKET................................................................................................2519 METHOD FOR INSTALLING SPROCKET..............................................................................................2519 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2521 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2521 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2522 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2523 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2523 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2524 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2528 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2529 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2529 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2531 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2532 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2533 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2535 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2535 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2537 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2539 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2539 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2541 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2544 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2544 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210-11E0, PC210LC-11E0).....................................................2547 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210NLC-11E0, PC230NHD-11E0).................................................2550 HYDRAULIC SYSTEM....................................................................................................................2554 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2554 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2554 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2556 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2559 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2559 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2560 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2562 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2562 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2565 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2569 METHOD FOR REMOVING MAIN PUMP ASSEMBLY......................................................................................2569 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY....................................................................................2572 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2576 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2576 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2583 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2591 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING..................................................................2591 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY................................................................................2592 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2596 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2596 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2596 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2598 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2598 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2599 REMOVE AND INSTALL QUICK COUPLER VALVE..........................................................................................2601 WORK EQUIPMENT......................................................................................................................2603 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2603 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2603 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2607 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2612 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2612 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2615 CAB AND ITS ATTACHMENTS.............................................................................................................2621 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2621 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY.................................................................................2621 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...............................................................................2629 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2636 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)......................................................................2638 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)....................................................................2638 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2648 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2648 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2651 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2657 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2657 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2664 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2671 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2671 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2677 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2684 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2684 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2686 REMOVE AND INSTALL SEAT BELT....................................................................................................2689 METHOD FOR REMOVING SEAT BELT...............................................................................................2689 METHOD FOR INSTALLING SEAT BELT.............................................................................................2690 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2691 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2691 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2696 ELECTRICAL SYSTEM...................................................................................................................2705 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2705 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2705 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2706 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2708 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2708 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2712 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY................................................................................2717 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY...........................................................................2717 METHOD FOR INSTALLING KomVision CONTROLLER..................................................................................2718 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2719 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2719 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2722 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2726 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR.................................................................................2726 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...............................................................................2727 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2728 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2728 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2728 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2730 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2730 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR........................................................................2731 REMOVE AND INSTALL SCR TEMPERATURE SENSOR.......................................................................................2732 METHOD FOR REMOVING SCR TEMPERATURE SENSOR..................................................................................2732 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................................................................................2734 REMOVE AND INSTALL KomVision CAMERA.............................................................................................2737 METHOD FOR REMOVING KomVision CAMERA........................................................................................2737 METHOD FOR INSTALLING KomVision CAMERA......................................................................................2738 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................2740 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...............................................................................2740 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY.............................................................................2743 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY.........................................................................2746 METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY....................................................................2746 METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY..................................................................2751 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS........................................................................2756 METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS...................................................................2756 METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS.................................................................2764 REMOVE AND INSTALL COMMUNICATION TERMINAL.......................................................................................2773 METHOD FOR REMOVING COMMUNICATION TERMINAL..................................................................................2773 METHOD FOR INSTALLING COMMUNICATION TERMINAL................................................................................2775 60 MAINTENANCE STANDARD.................................................................................................................2779 CONTENTS............................................................................................................................2780 ABBREVIATION LIST...................................................................................................................2781 ENGINE AND COOLING SYSTEM...........................................................................................................2787 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2787 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2788 POWER TRAIN.........................................................................................................................2790 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2790 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2791 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2793 MAINTENANCE STANDARD OF SPROCKET................................................................................................2795 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................2796 UNDERCARRIAGE AND FRAME.............................................................................................................2798 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2798 MAINTENANCE STANDARD OF IDLER...................................................................................................2800 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2802 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2803 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2804 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2807 MAINTENANCE STANDARD OF SWAMP SHOE..............................................................................................2808 MAINTENANCE STANDARD OF ROAD LINER..............................................................................................2809 HYDRAULIC SYSTEM....................................................................................................................2810 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2810 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2811 MAINTENANCE STANDARD OF LS-EPC VALVE............................................................................................2812 MAINTENANCE STANDARD OF PC-EPC VALVE............................................................................................2813 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2814 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2817 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2820 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2830 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2833 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2836 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE..........................................................2838 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2839 MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE........................................................................2840 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...................................................2842 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)....................................................2843 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2844 WORK EQUIPMENT......................................................................................................................2845 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2845 DIMENSION OF ARM............................................................................................................2850 DIMENSIONS OF BUCKET........................................................................................................2852 MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)...................................................................2854 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2855 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2856 80 APPENDIX.............................................................................................................................2857 CONTENTS............................................................................................................................2858 ABBREVIATION LIST...................................................................................................................2860 AIR CONDITIONER SYSTEM..............................................................................................................2866 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2866 AIR CONDITIONER COMPONENT.......................................................................................................2867 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................2869 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................2870 OUTLINE OF REFRIGERATION CYCLE..................................................................................................2871 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2873 AIR CONDITIONER UNIT............................................................................................................2873 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................2873 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2875 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................2877 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2878 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................2878 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................2878 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................2878 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................2879 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................2879 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................2879 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................2880 AIR CONDITIONER CONTROLLER......................................................................................................2881 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2881 COMPRESSOR......................................................................................................................2882 STRUCTURE OF COMPRESSOR.....................................................................................................2882 SPECIFICATIONS OF COMPRESSOR................................................................................................2882 FUNCTION OF COMPRESSOR......................................................................................................2882 CONDENSER.......................................................................................................................2883 STRUCTURE OF CONDENSER......................................................................................................2883 SPECIFICATIONS OF CONDENSER.................................................................................................2883 FUNCTION OF CONDENSER.......................................................................................................2883 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................2885 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2885 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2885 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................2885 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................2885 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................2887 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................2889 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................2891 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................2892 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2893 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2894 TESTING AIR LEAKAGE (DUCT)..........................................................................................................2898 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................2898 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................2900 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................2901 TEST VENT (MODE) CHANGEOVER.........................................................................................................2902 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................2902 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................2904 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................2904 TEST SUNLIGHT SENSOR................................................................................................................2905 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................2905 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................2906 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................2906 TEST RELAYS.........................................................................................................................2907 METHOD FOR TESTING RELAYS.......................................................................................................2907 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................2908 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................2909 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2912 FAILURE CODE [879AKA]...............................................................................................................2914 FAILURE CODE [879AKB]...............................................................................................................2915 FAILURE CODE [879BKA]...............................................................................................................2916 FAILURE CODE [879BKB]...............................................................................................................2918 FAILURE CODE [879CKA]...............................................................................................................2920 FAILURE CODE [879CKB]...............................................................................................................2921 FAILURE CODE [879DKZ]...............................................................................................................2922 FAILURE CODE [879EMC]...............................................................................................................2924 FAILURE CODE [879FMC]...............................................................................................................2925 FAILURE CODE [879GKX]...............................................................................................................2926 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................2928 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................2930 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................2933 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................2935 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................2937 CONNECTION OF SERVICE TOOL..........................................................................................................2940 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................2940 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................2942 HANDLE COMPRESSOR OIL...............................................................................................................2944 METHOD FOR REPLACING DESICCANT......................................................................................................2946 90 CIRCUIT DIAGRAMS.....................................................................................................................2949 CONTENTS............................................................................................................................2950 ABBREVIATION LIST...................................................................................................................2951 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2957 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2957 HYDRAULIC CIRCUIT DIAGRAM (1/2).................................................................................................2961 HYDRAULIC CIRCUIT DIAGRAM (2/2).................................................................................................2963 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2965 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................2965 ELECTRICAL CIRCUIT DIAGRAM (1/9)................................................................................................2969 ELECTRICAL CIRCUIT DIAGRAM (2/9)................................................................................................2971 ELECTRICAL CIRCUIT DIAGRAM (3/9)................................................................................................2973 ELECTRICAL CIRCUIT DIAGRAM (4/9)................................................................................................2975 ELECTRICAL CIRCUIT DIAGRAM (5/9)................................................................................................2977 ELECTRICAL CIRCUIT DIAGRAM (6/9)................................................................................................2979 ELECTRICAL CIRCUIT DIAGRAM (7/9)................................................................................................2981 ELECTRICAL CIRCUIT DIAGRAM (8/9)................................................................................................2983 ELECTRICAL CIRCUIT DIAGRAM (9/9)................................................................................................2985 INDEX....................................................................................................................................2987
DESCRIPTION:
KOMATSU PC210-11E0 PC210LC-11E0 PC210NLC-11E0 PC230NHD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00632 – 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 adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 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
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