Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06516-C3 PDF

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Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06516-C3 –  PDF DOWNLOAD

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Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06516-C3 –  PDF DOWNLOAD

Language : English
Pages : 2691
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06516-C3 –  PDF DOWNLOAD

• SERIAL NUMBERS C80001 and up

COVER 1
00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 56
PRACTICAL USE OF KOMTRAX 57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
HOW TO READ ELECTRICAL WIRE CODE 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 77
STANDARD TIGHTENING TORQUE TABLE 80
CONVERSION TABLE 87
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC210LC-11 . 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC210LC-11 . 102
SPECIFICATIONS 103
SPECIFICATIONS: PC210LC-11 103
WEIGHT TABLE 106
WEIGHT TABLE: PC210LC-11 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE . 109
10 STRUCTURE AND FUNCTION . 111
CONTENTS 112
ABBREVIATION LIST . 115
UREA SCR SYSTEM . 121
LAYOUT DRAWING OF UREA SCR SYSTEM . 122
UREA SCR SYSTEM DIAGRAM . 127
FUNCTION OF UREA SCR SYSTEM . 128
FUNCTION OF AdBlue/DEF SYSTEM . 128
INDUCEMENT STRATEGY . 130
COMPONENT PARTS OF UREA SCR SYSTEM 144
AdBlue/DEF MIXING TUBE 144
SCR ASSEMBLY 145
AdBlue/DEF TANK . 147
AdBlue/DEF PUMP . 149
AdBlue/DEF INJECTOR . 150
AdBlue/DEF HOSE . 151
AdBlue/DEF TANK HEATING VALVE . 152
BOOT-UP SYSTEM 153
LAYOUT DRAWING OF BOOT-UP SYSTEM 153
SYSTEM OPERATING LAMP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 155
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 155
BATTERY DISCONNECT SWITCH . 156
FUNCTION OF BATTERY DISCONNECT SWITCH . 156
ENGINE SYSTEM . 157
LAYOUT DRAWING OF ENGINE SYSTEM . 157
SPECIFICATIONS OF ENGINE SYSTEM . 158
FUNCTION OF ENGINE SYSTEM . 158
ENGINE CONTROL SYSTEM . 159
ENGINE CONTROL SYSTEM DIAGRAM . 159
FUNCTION OF ENGINE CONTROL SYSTEM . 160
AUTO-DECELERATION SYSTEM 162
AUTO-DECELERATION SYSTEM DIAGRAM 162
FUNCTION OF AUTO-DECELERATION SYSTEM 162
OPERATION OF AUTO-DECELERATION SYSTEM . 163
ENGINE AUTOMATIC WARM-UP SYSTEM . 164
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 164
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 165
OVERHEAT PREVENTION SYSTEM 166
OVERHEAT PREVENTION SYSTEM DIAGRAM 166
FUNCTION OF OVERHEAT PREVENTION SYSTEM 167
TURBOCHARGER PROTECTION SYSTEM 169
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 169
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 170
AUTOMATIC IDLE STOP SYSTEM 171
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 171
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 171
COMPONENT PARTS OF ENGINE SYSTEM 174
VGT . 174
EGR SYSTEM 178
EGR VALVE . 181
EGR COOLER 183
KCCV SYSTEM . 185
KCCV VENTILATOR . 187
KDPF 189
COOLING SYSTEM 193
LAYOUT DRAWING OF COOLING SYSTEM 193
SPECIFICATIONS OF COOLING SYSTEM 194
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 195
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 195
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 196
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 197
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 197
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 197
COMPONENT PARTS OF COOLING SYSTEM . 199
FAN CLUTCH 199
CONTROL SYSTEM 200
LAYOUT DRAWING OF CONTROL SYSTEM 200
MACHINE MONITOR SYSTEM 203
MACHINE MONITOR SYSTEM DIAGRAM 203
KOMTRAX SYSTEM 204
KOMTRAX SYSTEM DIAGRAM 204
FUNCTION OF KOMTRAX SYSTEM 204
COMPONENT PARTS OF CONTROL SYSTEM . 205
MACHINE MONITOR . 205
KOMTRAX TERMINAL 220
PUMP CONTROLLER . 222
RESISTOR FOR PC-EPC VALVE . 226
CAN TERMINATING RESISTOR 227
ENGINE CONTROLLER . 228
FUEL CONTROL DIAL . 235
HYDRAULIC SYSTEM 237
LAYOUT DRAWING OF HYDRAULIC SYSTEM 237
CLSS 243
STRUCTURE OF CLSS . 243
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 245
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 246
PRESSURE COMPENSATION CONTROL . 260
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 263
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 263
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 264
PUMP AND VALVE CONTROL SYSTEM . 269
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 269
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 270
COMPONENT PARTS OF HYDRAULIC SYSTEM . 272
HYDRAULIC TANK 272
MAIN PUMP . 274
CONTROL VALVE . 300
WORK EQUIPMENT SYSTEM . 357
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 357
STRUCTURE OF VALVE CONTROL 362
ONE-TOUCH POWER MAXIMIZING SYSTEM . 364
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 364
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 365
PPC LOCK SYSTEM . 366
PPC LOCK SYSTEM DIAGRAM . 366
FUNCTION OF PPC LOCK SYSTEM . 366
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 367
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 367
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 367
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 368
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 369
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 369
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 370
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 371
WORK EQUIPMENT AND SWING PPC VALVE 371
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 377
2ND-LINE ATTACHMENT PPC VALVE . 384
SOLENOID VALVE 386
ANTI-DROP VALVE FOR BOOM 389
ANTI-DROP VALVE FOR ARM . 393
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 398
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 400
PILOT CIRCUIT ACCUMULATOR . 402
ATTACHMENT CIRCUIT ACCUMULATOR 403
SWING SYSTEM 404
LAYOUT DRAWING OF SWING SYSTEM 404
SWING CONTROL SYSTEM DIAGRAM 408
FUNCTION OF SWING CONTROL SYSTEM 408
COMPONENT PARTS OF SWING SYSTEM . 412
SWING MOTOR . 412
SWING MACHINERY . 424
SWING CIRCLE 426
TRAVEL SYSTEM . 427
LAYOUT DRAWING OF TRAVEL SYSTEM . 427
TRAVEL CONTROL SYSTEM DIAGRAM . 431
FUNCTION OF TRAVEL CONTROL SYSTEM . 432
COMPONENT PARTS OF TRAVEL SYSTEM 433
TRAVEL MOTOR 433
FINAL DRIVE . 446
TRAVEL PPC VALVE 448
CENTER SWIVEL JOINT . 452
UNDERCARRIAGE AND FRAME . 454
LAYOUT DRAWING OF UNDERCARRIAGE . 454
SPECIFICATIONS OF UNDERCARRIAGE . 455
WORK EQUIPMENT 456
STRUCTURE OF WORK EQUIPMENT . 456
FUNCTION OF WORK EQUIPMENT 456
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
BUCKET CLEARANCE ADJUSTMENT SHIM 457
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 457
CAB AND ITS ATTACHMENTS . 458
ROPS CAB 458
STRUCTURE OF ROPS CAB . 458
FUNCTION OF ROPS CAB 458
CAB MOUNT . 459
STRUCTURE OF CAB MOUNT 459
FUNCTION OF CAB MOUNT . 459
CAB TIPPING STOPPER . 460
STRUCTURE OF CAB TIPPING STOPPER 460
FUNCTION OF CAB TIPPING STOPPER . 460
20 STANDARD VALUE TABLE . 461
CONTENTS 462
ABBREVIATION LIST . 463
STANDARD VALUE TABLE FOR ENGINE . 469
STANDARD VALUE TABLE FOR ENGINE: PC210LC-11 . 469
STANDARD VALUE TABLE FOR MACHINE 473
STANDARD VALUE TABLE FOR MACHINE: PC210LC-11 473
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 486
STANDARD VALUE TABLE FOR ELECTRICAL . 490
STANDARD VALUE TABLE FOR ELECTRICAL . 490
30 TESTING AND ADJUSTING 501
CONTENTS 502
ABBREVIATION LIST . 505
RELATED INFORMATION ON TESTING AND ADJUSTING 511
TOOLS FOR TESTING AND ADJUSTING . 511
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 517
ENGINE AND COOLING SYSTEM . 518
TEST ENGINE SPEED . 518
METHOD FOR TESTING ENGINE SPEED . 518
TEST BOOST PRESSURE . 521
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 521
METHOD FOR TESTING BOOST PRESSURE . 522
TEST EXHAUST GAS COLOR 523
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 523
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 524
TEST AND ADJUST VALVE CLEARANCE . 526
METHOD FOR TESTING VALVE CLEARANCE 526
METHOD FOR ADJUSTING VALVE CLEARANCE 527
TEST COMPRESSION PRESSURE . 528
METHOD FOR TESTING COMPRESSION PRESSURE . 528
TEST BLOWBY PRESSURE 533
METHOD FOR TESTING BLOWBY PRESSURE 533
TEST ENGINE OIL PRESSURE 535
METHOD FOR TESTING ENGINE OIL PRESSURE 535
TEST EGR VALVE AND VGT OIL PRESSURE . 536
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 536
TEST FUEL PRESSURE 538
METHOD FOR TESTING FUEL PRESSURE 539
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 544
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 545
BLEEDING AIR FROM FUEL SYSTEM . 551
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 551
TEST FUEL CIRCUIT FOR LEAKAGE . 552
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 552
HANDLE CYLINDER CUT-OUT MODE OPERATION 554
HANDLE NO-INJECTION CRANKING OPERATION 555
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 556
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 556
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 556
TEST COOLING FAN SPEED 558
METHOD FOR TESTING COOLING FAN SPEED 558
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 559
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 559
TEST SCR RELATED FUNCTIONS 560
TEST AdBlue/DEF PUMP RAISED PRESSURE 564
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 567
TEST AdBlue/DEF LINE HEATER RELAY 1 . 572
TEST AdBlue/DEF LINE HEATER RELAY 2 . 575
TEST AdBlue/DEF PUMP HEATER RELAY . 578
TEST AdBlue/DEF TANK HEATER VALVE . 581
TEST DENITRATION EFFICIENCY OF SCR 584
CLEAN AdBlue/DEF TANK . 588
METHOD FOR CLEANING AdBlue/DEF TANK . 588
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 592
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 592
POWER TRAIN . 594
TEST SWING CIRCLE BEARING CLEARANCE . 594
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 594
UNDERCARRIAGE AND FRAME . 595
TEST AND ADJUST TRACK TENSION . 595
METHOD FOR TESTING TRACK TENSION 595
METHOD FOR ADJUSTING TRACK TENSION 595
HYDRAULIC SYSTEM 597
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 597
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 597
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 598
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 599
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 605
TEST OIL PRESSURE OF CONTROL CIRCUIT 608
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 608
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 610
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 610
TEST PC-EPC VALVE OUTLET PRESSURE . 611
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 612
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 613
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 613
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 614
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 617
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 618
METHOD FOR ADJUSTING LS VALVE . 619
TEST OUTLET PRESSURE OF SOLENOID VALVE 620
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 620
OPERATING CONDITION OF SOLENOID VALVE . 621
TEST PPC VALVE OUTLET PRESSURE 624
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 624
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 626
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 626
TEST PUMP SWASH PLATE SENSOR 627
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 627
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 629
TEST OIL LEAKAGE 630
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 630
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 630
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 631
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 632
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 632
BLEED AIR FROM HYDRAULIC CIRCUIT 633
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 635
CAB AND ITS ATTACHMENTS . 637
TEST CAB TIPPING STOPPER 637
METHOD FOR TESTING CAB TIPPING STOPPER 637
METHOD FOR ADJUSTING MIRRORS 638
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 638
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 639
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 640
ELECTRICAL SYSTEM . 642
SET AND OPERATE MACHINE MONITOR . 642
OPERATOR MODE . 646
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 646
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 646
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 647
CHECKING FUNCTION OF SERVICE METER 647
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 647
SERVICE MODE 650
METHOD FOR OPERATING SERVICE MODE . 650
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 652
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 658
ABNORMALITY RECORD MENU . 670
METHOD FOR CONFIRMING MAINTENANCE RECORD 674
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 675
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 679
DEFAULT MENU 681
DIAGNOSTIC TESTS MENU . 688
ADJUSTMENT MENU . 698
METHOD FOR PERFORMING NO-INJECTION CRANKING . 716
KOMTRAX SETTINGS MENU . 718
METHOD FOR DISPLAYING SERVICE MESSAGE . 720
METHOD FOR STARTING UP KOMTRAX TERMINAL . 722
ADJUST REARVIEW CAMERA ANGLE 727
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 727
ADJUST KomVision CAMERA ANGLE . 730
SETTING OF KomVision (CAMERA CALIBRATION) . 731
METHOD FOR SETTING OF KomVision (CAMERA CALIBRATION) . 731
KomVision screen – Check 12 m visibility 744
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 747
HANDLE BATTERY DISCONNECT SWITCH 748
TEST DIODES . 749
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 749
METHOD FOR TESTING DIODE USING ANALOG TESTER 749
Pm CLINIC . 750
Pm CLINIC SERVICE . 750
Pm CLINIC CHECK SHEET . 752
40 TROUBLESHOOTING 763
CONTENTS 764
ABBREVIATION LIST . 775
RELATED INFORMATION ON TROUBLESHOOTING 781
GENERAL TROUBLESHOOTING POINTS 781
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 782
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 794
CHECKS BEFORE TROUBLESHOOTING . 796
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 798
WALK-AROUND CHECK . 798
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 800
CHECK FUEL LEVEL AND TYPE . 800
CHECK IMPURE INGREDIENT IN FUEL . 800
CHECK FUEL PREFILTER 801
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 801
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 802
CHECK MAIN FILTER . 803
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 805
CHECK COOLANT LEVEL (RESERVOIR TANK) 806
CHECK CLOGGING OF AIR CLEANER . 806
OUTER ELEMENT – CLEAN . 807
ELEMENTS – REPLACE 809
CHECK HYDRAULIC OIL LEVEL . 810
CHECK HYDRAULIC OIL STRAINER 811
CHECK HYDRAULIC FILTER 812
CHECK OIL LEVEL IN SWING MACHINERY CASE . 813
CHECK OIL LEVEL IN DAMPER CASE 814
CHECK OIL LEVEL IN FINAL DRIVE CASE . 814
BLEED AIR FROM FUEL SYSTEM 815
BLEED AIR FROM HYDRAULIC SYSTEM . 815
ELECTRICAL EQUIPMENT – CHECK METHOD . 815
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 823
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 833
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 836
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 840
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 842
CONNECTOR LIST AND LAYOUT . 845
CONNECTOR CONTACT IDENTIFICATION 858
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 898
FUSE LOCATION TABLE . 904
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 906
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 910
FAILURE CODES TABLE . 912
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 929
FAILURE CODE [879AKA] . 929
FAILURE CODE [879AKB] . 930
FAILURE CODE [879BKA] . 931
FAILURE CODE [879BKB] . 933
FAILURE CODE [879CKA] . 935
FAILURE CODE [879CKB] . 936
FAILURE CODE [879DKZ] . 937
FAILURE CODE [879EMC] . 939
FAILURE CODE [879FMC] . 940
FAILURE CODE [879GKX] . 941
FAILURE CODE [989L00] . 943
FAILURE CODE [989M00] . 944
FAILURE CODE [989N00] . 945
FAILURE CODE [A1U0N3] . 946
FAILURE CODE [A1U0N4] . 948
FAILURE CODE [A900FR] . 950
FAILURE CODE [A900N6] . 951
FAILURE CODE [A900NY] . 952
FAILURE CODE [AA10NX] . 953
FAILURE CODE [AB00KE] . 955
FAILURE CODE [AQ10N3] . 958
FAILURE CODE [AS00N3] . 960
FAILURE CODE [AS00R2] . 962
FAILURE CODE [AS00R3] . 963
FAILURE CODE [AS00R4] . 964
FAILURE CODE [AS00R5] . 965
FAILURE CODE [AS00R6] . 966
FAILURE CODE [AS00ZK] . 967
FAILURE CODE [AS10KM] . 968
FAILURE CODE [AS10NR] . 969
FAILURE CODE [AS10NT] . 970
FAILURE CODE [B@BAZG] . 971
FAILURE CODE [B@BAZK] . 972
FAILURE CODE [B@BCNS] . 974
FAILURE CODE [B@BCQA] . 975
FAILURE CODE [B@BCZK] . 977
FAILURE CODE [B@HANS] . 979
FAILURE CODE [CA115] 980
FAILURE CODE [CA122] 981
FAILURE CODE [CA123] 983
FAILURE CODE [CA131] 985
FAILURE CODE [CA132] 987
FAILURE CODE [CA144] 989
FAILURE CODE [CA145] 991
FAILURE CODE [CA153] 993
FAILURE CODE [CA154] 996
FAILURE CODE [CA187] 998
FAILURE CODE [CA221] 1000
FAILURE CODE [CA222] 1002
FAILURE CODE [CA227] 1004
FAILURE CODE [CA234] 1005
FAILURE CODE [CA238] 1006
FAILURE CODE [CA239] 1008
FAILURE CODE [CA249] 1010
FAILURE CODE [CA256] 1012
FAILURE CODE [CA271] 1014
FAILURE CODE [CA272] 1016
FAILURE CODE [CA322] 1018
FAILURE CODE [CA323] 1020
FAILURE CODE [CA324] 1022
FAILURE CODE [CA325] 1024
FAILURE CODE [CA331] 1026
FAILURE CODE [CA332] 1028
FAILURE CODE [CA343] 1030
FAILURE CODE [CA351] 1031
FAILURE CODE [CA352] 1032
FAILURE CODE [CA356] 1035
FAILURE CODE [CA357] 1037
FAILURE CODE [CA386] 1039
FAILURE CODE [CA428] 1040
FAILURE CODE [CA429] 1042
FAILURE CODE [CA435] 1044
FAILURE CODE [CA441] 1046
FAILURE CODE [CA442] 1048
FAILURE CODE [CA449] 1049
FAILURE CODE [CA451] 1050
FAILURE CODE [CA452] 1052
FAILURE CODE [CA488] 1054
FAILURE CODE [CA515] 1055
FAILURE CODE [CA516] 1057
FAILURE CODE [CA553] 1059
FAILURE CODE [CA555] 1060
FAILURE CODE [CA556] 1061
FAILURE CODE [CA559] 1062
FAILURE CODE [CA595] 1065
FAILURE CODE [CA687] 1066
FAILURE CODE [CA689] 1068
FAILURE CODE [CA691] 1071
FAILURE CODE [CA692] 1073
FAILURE CODE [CA697] 1075
FAILURE CODE [CA698] 1076
FAILURE CODE [CA731] 1077
FAILURE CODE [CA778] 1079
FAILURE CODE [CA1117] .1084
FAILURE CODE [CA1664] .1085
FAILURE CODE [CA1669] .1087
FAILURE CODE [CA1673] .1088
FAILURE CODE [CA1677] .1089
FAILURE CODE [CA1678] .1090
FAILURE CODE [CA1682] .1091
FAILURE CODE [CA1683] .1093
FAILURE CODE [CA1684] .1095
FAILURE CODE [CA1686] .1097
FAILURE CODE [CA1691] .1098
FAILURE CODE [CA1694] .1101
FAILURE CODE [CA1695] .1104
FAILURE CODE [CA1696] .1105
FAILURE CODE [CA1712] .1107
FAILURE CODE [CA1713] .1110
FAILURE CODE [CA1714] .1112
FAILURE CODE [CA1715] .1113
FAILURE CODE [CA1776] .1114
FAILURE CODE [CA1777] .1117
FAILURE CODE [CA1843] .1120
FAILURE CODE [CA1844] .1122
FAILURE CODE [CA1879] .1125
FAILURE CODE [CA1881] .1127
FAILURE CODE [CA1883] .1129
FAILURE CODE [CA1885] .1132
FAILURE CODE [CA1887] .1134
FAILURE CODE [CA1921] .1136
FAILURE CODE [CA1922] .1139
FAILURE CODE [CA1942] .1144
FAILURE CODE [CA1993] .1145
FAILURE CODE [CA2185] .1148
FAILURE CODE [CA2186] .1149
FAILURE CODE [CA2249] .1151
FAILURE CODE [CA2271] .1152
FAILURE CODE [CA2272] .1155
FAILURE CODE [CA2288] .1158
FAILURE CODE [CA2311] .1159
FAILURE CODE [CA2349] .1160
FAILURE CODE [CA2353] .1163
FAILURE CODE [CA2357] .1165
FAILURE CODE [CA2381] .1166
FAILURE CODE [CA2382] .1169
FAILURE CODE [CA2383] .1172
FAILURE CODE [CA2386] .1175
FAILURE CODE [CA2387] .1177
FAILURE CODE [CA2555] .1178
FAILURE CODE [CA2556] .1181
FAILURE CODE [CA2637] .1184
FAILURE CODE [CA2639] .1186
FAILURE CODE [CA2771] .1189
FAILURE CODE [CA2777] .1195
FAILURE CODE [CA2976] .1198
FAILURE CODE [CA3133] .1200
FAILURE CODE [CA3134] .1203
FAILURE CODE [CA3135] .1205
FAILURE CODE [CA3142] .1208
FAILURE CODE [CA3143] .1209
FAILURE CODE [CA3144] .1210
FAILURE CODE [CA3146] .1212
FAILURE CODE [CA3147] .1213
FAILURE CODE [CA3148] .1214
FAILURE CODE [CA3151] .1216
FAILURE CODE [CA3165] .1222
FAILURE CODE [CA3229] .1224
FAILURE CODE [CA3231] .1226
FAILURE CODE [CA3232] .1228
FAILURE CODE [CA3235] .1232
FAILURE CODE [CA3239] .1234
FAILURE CODE [CA3241] .1237
FAILURE CODE [CA3242] .1240
FAILURE CODE [CA3251] .1243
FAILURE CODE [CA3253] .1245
FAILURE CODE [CA3254] .1248
FAILURE CODE [CA3255] .1251
FAILURE CODE [CA3256] .1255
FAILURE CODE [CA3311] .1257
FAILURE CODE [CA3312] .1259
FAILURE CODE [CA3313] .1262
FAILURE CODE [CA3314] .1263
FAILURE CODE [CA3315] .1264
FAILURE CODE [CA3316] .1266
FAILURE CODE [CA3317] .1267
FAILURE CODE [CA3318] .1268
FAILURE CODE [CA3319] .1270
FAILURE CODE [CA3321] .1271
FAILURE CODE [CA3322] .1273
FAILURE CODE [CA3419] .1275
FAILURE CODE [CA3421] .1277
FAILURE CODE [CA3497] .1279
FAILURE CODE [CA3498] .1280
FAILURE CODE [CA3543] .1281
FAILURE CODE [CA3545] .1287
FAILURE CODE [CA3547] .1289
FAILURE CODE [CA3558] .1290
FAILURE CODE [CA3559] .1292
FAILURE CODE [CA3562] .1294
FAILURE CODE [CA3563] .1296
FAILURE CODE [CA3567] .1299
FAILURE CODE [CA3568] .1302
FAILURE CODE [CA3571] .1306
FAILURE CODE [CA3572] .1308
FAILURE CODE [CA3574] .1310
FAILURE CODE [CA3575] .1312
FAILURE CODE [CA3577] .1314
FAILURE CODE [CA3578] .1316
FAILURE CODE [CA3582] .1318
FAILURE CODE [CA3583] .1324
FAILURE CODE [CA3596] .1326
FAILURE CODE [CA3649] .1328
FAILURE CODE [CA3681] .1330
FAILURE CODE [CA3682] .1335
FAILURE CODE [CA3713] .1341
FAILURE CODE [CA3717] .1344
FAILURE CODE [CA3718] .1345
FAILURE CODE [CA3725] .1346
FAILURE CODE [CA3741] .1349
FAILURE CODE [CA3748] .1350
FAILURE CODE [CA3751] .1352
FAILURE CODE [CA3755] .1354
FAILURE CODE [CA3866] .1356
FAILURE CODE [CA3867] .1359
FAILURE CODE [CA3868] .1362
FAILURE CODE [CA3899] .1366
FAILURE CODE [CA3911] .1368
FAILURE CODE [CA3912] .1372
FAILURE CODE [CA3932] .1374
FAILURE CODE [CA3933] .1376
FAILURE CODE [CA3934] .1378
FAILURE CODE [CA3935] .1381
FAILURE CODE [CA3936] .1383
FAILURE CODE [CA4151] .1385
FAILURE CODE [CA4152] .1389
FAILURE CODE [CA4155] .1393
FAILURE CODE [CA4156] .1395
FAILURE CODE [CA4157] .1398
FAILURE CODE [CA4158] .1400
FAILURE CODE [CA4159] .1401
FAILURE CODE [CA4161] .1402
FAILURE CODE [CA4162] .1405
FAILURE CODE [CA4163] .1408
FAILURE CODE [CA4164] .1409
FAILURE CODE [CA4165] .1411
FAILURE CODE [CA4166] .1413
FAILURE CODE [CA4168] .1414
FAILURE CODE [CA4169] .1417
FAILURE CODE [CA4171] .1419
FAILURE CODE [CA4249] .1422
FAILURE CODE [CA4251] .1424
FAILURE CODE [CA4259] .1426
FAILURE CODE [CA4261] .1429
FAILURE CODE [CA4277] .1432
FAILURE CODE [CA4281] .1435
FAILURE CODE [CA4459] .1438
FAILURE CODE [CA4461] .1441
FAILURE CODE [CA4658] .1444
FAILURE CODE [CA4731] .1448
FAILURE CODE [CA4732] .1449
FAILURE CODE [CA4739] .1450
FAILURE CODE [CA4768] .1451
FAILURE CODE [CA4769] .1453
FAILURE CODE [CA4842] .1456
FAILURE CODE [CA4952] .1459
FAILURE CODE [CA5115] .1461
FAILURE CODE [CA5179] .1464
FAILURE CODE [CA5181] .1466
FAILURE CODE [CA5383] .1468
FAILURE CODE [D110KB] .1470
FAILURE CODE [D19JKZ] .1472
FAILURE CODE [D811MC] .1475
FAILURE CODE [D862KA] .1476
FAILURE CODE [D8ALKA] .1477
FAILURE CODE [D8ALKB] .1479
FAILURE CODE [D8AQKR] .1481
FAILURE CODE [DA20MC] .1483
FAILURE CODE [DA22KK] .1484
FAILURE CODE [DA25KP] .1487
FAILURE CODE [DA26KP] .1490
FAILURE CODE [DA29KQ] .1492
FAILURE CODE [DA2LKA] .1494
FAILURE CODE [DA2LKB] .1496
FAILURE CODE [DA2QKR] .1498
FAILURE CODE [DA2RKR] .1501
FAILURE CODE [DAF0MB] .1502
FAILURE CODE [DAF0MC] .1503
FAILURE CODE [DAF8KB] .1504
FAILURE CODE [DAF9KQ] .1506
FAILURE CODE [DAFGMC] .1507
FAILURE CODE [DAFLKA] .1508
FAILURE CODE [DAFLKB] .1510
FAILURE CODE [DAFQKR] .1512
FAILURE CODE [DAZ9KQ] .1513
FAILURE CODE [DAZQKR] .1514
FAILURE CODE [DB2QKR] .1519
FAILURE CODE [DB2RKR] .1524
FAILURE CODE [DDNRKA] .1529
FAILURE CODE [DDNRKY] .1531
FAILURE CODE [DDNS00] .1533
FAILURE CODE [DGH2KA] .1535
FAILURE CODE [DGH2KB] .1537
FAILURE CODE [DHA4KA] .1539
FAILURE CODE [DHAAMA] .1541
FAILURE CODE [DHACMA] .1543
FAILURE CODE [DHPAMA] .1545
FAILURE CODE [DHPBMA] .1548
FAILURE CODE [DHS3MA] .1551
FAILURE CODE [DHS4MA] .1554
FAILURE CODE [DHS8MA] .1557
FAILURE CODE [DHS9MA] .1560
FAILURE CODE [DHSAMA] .1563
FAILURE CODE [DHSBMA] .1566
FAILURE CODE [DHSCMA] .1569
FAILURE CODE [DHSDMA] .1572
FAILURE CODE [DHSFMA] .1575
FAILURE CODE [DHSGMA] .1578
FAILURE CODE [DHSHMA] .1581
FAILURE CODE [DHSJMA] .1584
FAILURE CODE [DKR0MA] .1587
FAILURE CODE [DKR1MA] .1590
FAILURE CODE [DKULKA] .1593
FAILURE CODE [DKULKB] .1595
FAILURE CODE [DKULKY] .1597
FAILURE CODE [DLM5KA] .1599
FAILURE CODE [DLM5MB] .1601
FAILURE CODE [DR21KX] .1603
FAILURE CODE [DR31KX] .1605
FAILURE CODE [DV20KB] .1607
FAILURE CODE [DW43KA] .1609
FAILURE CODE [DW43KB] .1611
FAILURE CODE [DW43KY] .1613
FAILURE CODE [DW45KA] .1615
FAILURE CODE [DW45KB] .1618
FAILURE CODE [DW45KY] .1621
FAILURE CODE [DW4CKY] .1623
FAILURE CODE [DW91KA] .1625
FAILURE CODE [DW91KB] .1627
FAILURE CODE [DW91KY] .1629
FAILURE CODE [DWA2KA] .1631
FAILURE CODE [DWA2KB] .1633
FAILURE CODE [DWA2KY] .1635
FAILURE CODE [DWK0KA] .1637
FAILURE CODE [DWK0KB] .1639
FAILURE CODE [DWK0KY] .1641
FAILURE CODE [DWK2KA] .1643
FAILURE CODE [DWK2KB] .1645
FAILURE CODE [DWK2KY] .1647
FAILURE CODE [DWK8KA] .1649
FAILURE CODE [DWK8KB] .1651
FAILURE CODE [DWK8KY] .1653
FAILURE CODE [DWN5KA] .1655
FAILURE CODE [DWN5KB] .1657
FAILURE CODE [DWN5KY] .1659
FAILURE CODE [DXA8KA] .1661
FAILURE CODE [DXA8KB] .1663
FAILURE CODE [DXA9KA] .1665
FAILURE CODE [DXA9KB] .1667
FAILURE CODE [DXE0KA] .1669
FAILURE CODE [DXE0KB] .1670
FAILURE CODE [DXE4KA] .1672
FAILURE CODE [DXE4KB] .1674
FAILURE CODE [DXE4KY] .1676
FAILURE CODE [DXE5KA] .1678
FAILURE CODE [DXE5KB] .1680
FAILURE CODE [DXE6KA] .1682
FAILURE CODE [DXE6KB] .1684
FAILURE CODE [DXE7KA] .1686
FAILURE CODE [DXE7KB] .1688
FAILURE CODE [DXE7KY] .1690
FAILURE CODE [DXE8KA] .1692
FAILURE CODE [DXE8KB] .1694
FAILURE CODE [DXE8KY] .1696
FAILURE CODE [DXE9KA] .1698
FAILURE CODE [DXE9KB] .1700
FAILURE CODE [DXE9KY] .1702
FAILURE CODE [DXEAKA] .1704
FAILURE CODE [DXEAKB] .1706
FAILURE CODE [DXEAKY] .1708
FAILURE CODE [DY20KA] .1710
FAILURE CODE [DY20MA] .1712
FAILURE CODE [DY2CKB] .1714
FAILURE CODE [DY2DKB] .1717
FAILURE CODE [DY2EKB] .1719
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1721
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1721
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1727
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1730
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1732
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1734
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1737
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1738
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1739
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1740
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1741
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1742
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1743
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1744
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1745
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1746
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1747
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1748
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1750
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1751
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1752
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1753
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1755
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1756
E-24 FUNCTION SWITCH DOES NOT OPERATE .1757
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1758
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1759
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1760
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1761
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1762
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1763
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1764
E-32 ALARM BUZZER CANNOT BE CANCELED 1766
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1767
E-34 SERVICE MODE CANNOT BE SELECTED 1768
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1769
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1772
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1774
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1777
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1779
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1782
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1783
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1785
E-43 HORN DOES NOT SOUND 1786
E-44 HORN DOES NOT STOP SOUNDING 1789
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1791
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1792
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1794
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1795
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1796
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1797
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1798
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1799
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1800
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1801
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1802
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1803
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1805
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1806
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1807
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1807
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1808
FAILURE MODE AND CAUSE TABLE 1810
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1822
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1823
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1826
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1827
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1828
H-6 SPEED OR POWER OF BOOM IS LOW .1830
H-7 ARM SPEED OR POWER IS LOW .1834
H-8 BUCKET SPEED OR POWER IS LOW 1839
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1842
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1843
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1845
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1847
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1848
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1849
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1850
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1851
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1852
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1853
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1854
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1855
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1856
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1858
H-23 TRAVEL SPEED IS LOW 1861
H-24 ONE OF TRACKS DOES NOT RUN .1863
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1864
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1865
H-27 SWINGS ONLY IN ONE DIRECTION .1866
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1867
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1868
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1869
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1870
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1871
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1872
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1873
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1874
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1875
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1876
TROUBLESHOOTING OF ENGINE (S-MODE) 1877
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1877
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1878
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1879
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1880
S-4 ENGINE STARTABILITY IS POOR .1882
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1884
S-6 ENGINE STOPS DURING OPERATION .1886
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1888
S-8 ENGINE LACKS POWER 1889
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1891
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1893
S-11 OIL BECOMES CONTAMINATED QUICKLY .1894
S-12 FUEL CONSUMPTION IS EXCESSIVE 1895
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1896
S-14 OIL PRESSURE DROPS .1897
S-15 FUEL MIXES INTO ENGINE OIL .1899
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1900
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1901
S-18 UNUSUAL NOISE IS HEARD .1902
S-19 VIBRATION IS EXCESSIVE .1903
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1904
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1905
S-22 ACTIVE REGENERATION TAKES TIME .1907
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1908
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1909
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1911
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1912
50 DISASSEMBLY AND ASSEMBLY .1913
CONTENTS 1914
ABBREVIATION LIST .1919
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1925
HOW TO READ THIS MANUAL .1925
COATING MATERIALS LIST 1927
SPECIAL TOOLS LIST 1931
SKETCHES OF SPECIAL TOOLS .1943
ENGINE AND COOLING SYSTEM .1949
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1949
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1949
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1952
REMOVE AND INSTALL INJECTOR ASSEMBLY 1955
METHOD FOR REMOVING INJECTOR ASSEMBLY .1955
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1960
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1968
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1969
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1978
REMOVE AND INSTALL EGR VALVE ASSEMBLY .1994
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1994
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1995
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1997
METHOD FOR REMOVING EGR COOLER ASSEMBLY .1997
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2001
REMOVE AND INSTALL STARTER ASSEMBLY .2006
METHOD FOR REMOVING STARTER ASSEMBLY 2006
METHOD FOR INSTALLING STARTER ASSEMBLY 2007
REMOVE AND INSTALL ALTERNATOR BELT 2010
METHOD FOR REMOVING ALTERNATOR BELT .2010
METHOD FOR INSTALLING ALTERNATOR BELT .2012
REMOVE AND INSTALL RADIATOR ASSEMBLY 2014
METHOD FOR REMOVING RADIATOR ASSEMBLY .2014
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2016
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2019
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2019
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2022
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2025
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2025
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2027
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2029
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2029
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2033
REMOVE AND INSTALL FAN 2037
METHOD FOR INSTALLING FAN .2037
METHOD FOR REMOVING FAN .2037
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2038
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2038
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2047
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2059
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2059
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2062
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2066
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2066
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2067
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2070
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2070
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2070
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2072
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2072
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2074
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2079
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2079
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2083
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2087
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2087
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2093
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2099
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2099
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2105
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2111
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2111
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2111
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2113
METHOD FOR REMOVING AdBlue/DEF STRAINER .2113
METHOD FOR INSTALLING AdBlue/DEF STRAINER .2113
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2114
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2114
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2116
REMOVE AND INSTALL KDPF ASSEMBLY 2119
METHOD FOR REMOVING KDPF ASSEMBLY .2119
METHOD FOR INSTALLING KDPF ASSEMBLY .2121
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2123
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2124
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2127
REMOVE AND INSTALL SCR ASSEMBLY .2132
METHOD FOR REMOVING SCR ASSEMBLY 2132
METHOD FOR INSTALLING SCR ASSEMBLY 2134
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2136
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2136
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2142
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2148
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2148
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2156
REMOVE AND INSTALL KCCV ASSEMBLY 2164
METHOD FOR REMOVING KCCV ASSEMBLY .2164
METHOD FOR INSTALLING KCCV ASSEMBLY .2166
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2171
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2171
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2177
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2183
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2183
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2186
REMOVE AND INSTALL AdBlue/DEF PUMP 2189
METHOD FOR REMOVING AdBlue/DEF PUMP .2189
METHOD FOR INSTALLING AdBlue/DEF PUMP .2192
REMOVE AND INSTALL AdBlue/DEF HOSE 2195
METHOD FOR REMOVING AdBlue/DEF HOSE .2195
METHOD FOR INSTALLING AdBlue/DEF HOSE .2202
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2208
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2208
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2209
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2211
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2211
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2213
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2216
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2216
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2217
POWER TRAIN .2218
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2218
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2218
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2219
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2221
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2221
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2225
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2234
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2234
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2236
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2240
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2240
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2244
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2251
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2251
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2251
UNDERCARRIAGE AND FRAME .2253
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2253
METHOD FOR SEPARATING TRACK ASSEMBLY 2253
METHOD FOR INSTALLING TRACK ASSEMBLY 2255
REMOVE AND INSTALL SPROCKET .2258
METHOD FOR REMOVING SPROCKET 2258
METHOD FOR INSTALLING SPROCKET 2258
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2260
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2260
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2261
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2262
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2262
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2263
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2267
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2267
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2268
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2270
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2271
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2272
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2274
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2274
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2275
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2278
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2278
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2280
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2283
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2283
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2286
HYDRAULIC SYSTEM 2290
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2290
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2290
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2292
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2295
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2295
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2296
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2298
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2298
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2300
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2303
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2303
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2306
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2309
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2309
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2316
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2324
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2324
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2325
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2329
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2329
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2329
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2331
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2331
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2332
WORK EQUIPMENT 2334
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2334
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2334
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2338
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2343
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2343
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2345
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2346
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2346
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2348
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2349
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2349
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2349
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2350
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2350
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2353
CAB AND ITS ATTACHMENTS .2359
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2359
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2359
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2365
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2372
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2374
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2374
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2384
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2384
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2387
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2393
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2393
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2400
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2407
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2407
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2412
REMOVE AND INSTALL OPERATOR’S SEAT 2418
METHOD FOR REMOVING OPERATOR’S SEAT .2418
METHOD FOR INSTALLING OPERATOR’S SEAT .2420
REMOVE AND INSTALL SEAT BELT 2423
METHOD FOR REMOVING SEAT BELT .2423
METHOD FOR INSTALLING SEAT BELT .2424
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2425
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2425
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2430
ELECTRICAL SYSTEM .2439
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2439
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2439
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2440
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2442
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2442
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2446
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2451
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2451
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2454
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2458
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2458
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2459
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2460
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2460
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2460
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2462
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2462
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2463
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2464
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2464
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2466
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2468
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2468
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2471
60 MAINTENANCE STANDARD .2475
CONTENTS 2476
ABBREVIATION LIST .2477
ENGINE AND COOLING SYSTEM .2483
MAINTENANCE STANDARD OF ENGINE MOUNT 2483
MAINTENANCE STANDARD OF COOLING SYSTEM 2484
POWER TRAIN .2486
MAINTENANCE STANDARD OF SWING CIRCLE 2486
MAINTENANCE STANDARD OF SWING MACHINERY .2487
MAINTENANCE STANDARD OF FINAL DRIVE .2489
MAINTENANCE STANDARD OF SPROCKET 2491
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2492
UNDERCARRIAGE AND FRAME .2494
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2494
MAINTENANCE STANDARD OF IDLER .2496
MAINTENANCE STANDARD OF TRACK ROLLER 2498
MAINTENANCE STANDARD OF CARRIER ROLLER 2499
MAINTENANCE STANDARD OF TRACK SHOE 2500
MAINTENANCE STANDARD OF TRIPLE SHOE .2503
MAINTENANCE STANDARD OF SWAMP SHOE 2504
MAINTENANCE STANDARD OF ROAD LINER 2505
HYDRAULIC SYSTEM 2506
MAINTENANCE STANDARD OF HYDRAULIC TANK 2506
MAINTENANCE STANDARD OF MAIN PUMP .2507
MAINTENANCE STANDARD OF LS-EPC VALVE 2508
MAINTENANCE STANDARD OF PC-EPC VALVE 2509
MAINTENANCE STANDARD OF SWING MOTOR .2510
MAINTENANCE STANDARD OF TRAVEL MOTOR 2513
MAINTENANCE STANDARD OF CONTROL VALVE .2516
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2526
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2528
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2530
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2533
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2536
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2537
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2539
MAINTENANCE STANDARD OF SOLENOID VALVE 2541
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2542
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2543
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2544
WORK EQUIPMENT 2545
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2545
DIMENSION OF ARM 2550
DIMENSIONS OF BUCKET 2552
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2554
MAINTENANCE STANDARD OF ARM CYLINDER 2555
MAINTENANCE STANDARD OF BUCKET CYLINDER .2556
80 APPENDIX .2557
CONTENTS 2558
ABBREVIATION LIST .2560
AIR CONDITIONER SYSTEM 2566
PRECAUTIONS FOR REFRIGERANT .2566
AIR CONDITIONER COMPONENT .2567
SPECIFICATIONS OF AIR CONDITIONER .2569
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2570
OUTLINE OF REFRIGERATION CYCLE 2571
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2573
AIR CONDITIONER UNIT 2573
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2573
FUNCTION OF AIR CONDITIONER UNIT 2575
COMPONENT PARTS OF AIR CONDITIONER UNIT .2577
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2578
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2578
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2578
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2578
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2579
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2579
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2579
FUNCTION OF DUAL PRESSURE SWITCH 2580
AIR CONDITIONER CONTROLLER 2581
STRUCTURE OF AIR CONDITIONER CONTROLLER .2581
COMPRESSOR 2582
STRUCTURE OF COMPRESSOR .2582
SPECIFICATIONS OF COMPRESSOR 2582
FUNCTION OF COMPRESSOR 2582
CONDENSER .2583
STRUCTURE OF CONDENSER 2583
SPECIFICATIONS OF CONDENSER .2583
FUNCTION OF CONDENSER .2583
SENSORS FOR AIR CONDITIONER SYSTEM 2585
STRUCTURE OF SUNLIGHT SENSOR 2585
FUNCTION OF SUNLIGHT SENSOR .2585
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2585
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2585
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2587
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2589
AIR CONDITIONER SYSTEM DIAGRAM 2591
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2592
FUNCTION OF AIR CONDITIONER CONTROLLER 2593
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2594
TESTING AIR LEAKAGE (DUCT) 2598
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2598
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2600
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2601
TEST VENT (MODE) CHANGEOVER .2602
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2602
TESTING FRESH/RECIRC AIR CHANGEOVER .2604
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2604
TEST SUNLIGHT SENSOR 2605
METHOD FOR TESTING SUNLIGHT SENSOR 2605
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2606
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2606
TEST RELAYS .2607
METHOD FOR TESTING RELAYS .2607
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2608
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2609
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2612
FAILURE CODE [879AKA] .2614
FAILURE CODE [879AKB] .2615
FAILURE CODE [879BKA] .2616
FAILURE CODE [879BKB] .2618
FAILURE CODE [879CKA] .2620
FAILURE CODE [879CKB] .2621
FAILURE CODE [879DKZ] .2622
FAILURE CODE [879EMC] .2624
FAILURE CODE [879FMC] .2625
FAILURE CODE [879GKX] .2626
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2628
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2630
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2633
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2635
TROUBLESHOOTING USING GAUGE PRESSURE 2637
CONNECTION OF SERVICE TOOL 2640
METHOD FOR CONNECTING SERVICE TOOL 2640
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2642
HANDLE COMPRESSOR OIL .2644
METHOD FOR REPLACING DESICCANT 2646
90 CIRCUIT DIAGRAMS .2649
CONTENTS 2650
ABBREVIATION LIST .2651
HYDRAULIC CIRCUIT DIAGRAM .2657
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2657
HYDRAULIC CIRCUIT DIAGRAM .2661
ELECTRICAL CIRCUIT DIAGRAM 2663
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2663
ELECTRICAL CIRCUIT DIAGRAM (1/7) 2667
ELECTRICAL CIRCUIT DIAGRAM (2/7) 2668
ELECTRICAL CIRCUIT DIAGRAM (3/7) 2669
ELECTRICAL CIRCUIT DIAGRAM (4/7) 2670
ELECTRICAL CIRCUIT DIAGRAM (5/7) 2671
ELECTRICAL CIRCUIT DIAGRAM (6/7) 2672
ELECTRICAL CIRCUIT DIAGRAM (7/7) 2673
INDEX 2674

DESCRIPTION:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06516-C3 –  PDF DOWNLOAD

• SERIAL NUMBERS C80001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL

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

G.B 30/12/24