Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06805-09 PDF

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Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06805-09  – PDF DOWNLOAD

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Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06805-09  – PDF DOWNLOAD

Language : English
Pages : 2994
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06805-09  – PDF DOWNLOAD

• SERIAL NUMBERS 502361 and up

Cover . 1
00 Index and Foreword 3
Index 4
Abbreviation List 22
Foreword, Safety, Basic Information 25
How to Read the Shop Manual 25
Safety Notice for Operation 27
Precautions to Prevent Fire 35
Procedures If Fire Occurs 37
Precautions When You Discard Waste Materials . 38
Procedures for Exhaust Gas Regulations . 39
Precautions for DEF 40
General Character and Precautions for Handling . 40
Precautions When You Add . 40
Precautions for Storage 40
Precautions for Fire Hazard and Leakage 40
Other Precautions 40
Store DEF 41
Precautions When You Handle Hydraulic Equipment 42
Precautions When You Disconnect and Connect Pipings 45
Precautions When You Handle Electrical Equipment . 52
Precautions When You Handle Fuel System Equipment 54
Precautions When You Handle Intake System Equipment 55
Practical Use of KOMTRAX . 56
Disconnect and Connect Push-Pull Type Coupler 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 59
Precautions for Disconnection and Connection of Connectors . 61
Disconnect and Connect Deutsch Connector . 65
How to Disconnect and Connect Slide Lock Type Connector 66
Disconnect and Connect Connector with Lock to Pull . 68
Disconnect and Connect Connector with Lock to Push . 69
Disconnect and Connect Connector with Housing to Rotate 71
How to Read the Codes for Electric Cable . 72
Explanation of Terms for Maintenance Standard 76
Standard Tightening Torque Table . 79
Conversion Table . 86
01 Specification . 91
Table of Contents 92
Specifications . 93
Specification Drawing 93
Specification Drawing: PC210LC-11 93
Working Range Drawings . 95
Working Range: PC210LC-11 95
Specifications . 96
Specifications: PC210LC-11 . 96
Weight Table . 99
Weight Table: PC210LC-11 . 99
Table of Fuel, Coolant, and Lubricants . 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 108
Layout Drawing of Urea SCR System 109
Urea SCR System Diagram 114
Function of Urea SCR System 115
Function of DEF System . 115
Inducement Strategy 117
Component Parts of Urea SCR System . 125
DEF Mixing Tube 125
SCR Assembly . 125
DEF Tank . 128
DEF Pump . 130
DEF Injector . 131
DEF Hose . 132
DEF Tank Heating Valve . 133
Boot-up System . 134
Layout Drawing of Boot-up System . 134
System Operating Lamp System . 136
System Diagram of System Operating Lamp System . 136
Function of Operation Lamp System 136
Battery Isolator . 138
Function of Battery Isolator . 138
Engine System 139
Layout Drawing of Engine System 139
Specifications of Engine System 140
Function of Engine System 140
Engine Control System 141
System Diagram of Engine Control . 141
Function of Engine Control System 142
Auto-Deceleration System . 145
System Diagram of Auto-Deceleration System . 145
Function of Auto-Deceleration System . 145
Operation of Auto-Deceleration System 146
Engine Automatic Warm-up System 147
System Diagram of Engine Automatic Warm-up System 147
Function of Engine Automatic Warm-up System 148
Overheat Prevention System . 149
Overheat Prevention System Diagram . 149
Function of Overheat Prevention System . 150
Turbocharger Protection System . 152
System Diagram of Turbocharger Protection System . 152
Function of Turbocharger Protection System . 153
Automatic Idle Stop System . 154
System Diagram of Automatic Idle Stop System . 154
Function of Automatic Idle Stop System . 154
Component Parts of Engine System . 157
VGT 157
EGR System . 161
EGR Valve 163
EGR Cooler . 165
KCCV System 166
KCCV Ventilator 168
KDPF . 170
Cooling System . 175
Layout Drawing of Cooling System . 175
Specifications of Cooling System . 176
Fan Speed Control System of Fan Clutch . 177
Fan Speed Control System Diagram of Fan Clutch . 177
Function of Fan Speed Control System of Fan Clutch . 178
Engine Output Control System of Fan Clutch . 179
Engine Output Control System Diagram of Fan Clutch . 179
Function of Engine Output Control System of Fan Clutch . 179
Component Parts of Cooling System 181
Fan Clutch . 181
Control System . 182
Layout Drawing of Control System . 182
Machine Monitor System . 185
System Diagram of Machine Monitor System . 185
Function of Machine Monitor System . 185
KomVision System . 187
Layout Drawing of KomVision System . 187
System Diagram of KomVision System . 189
Function of KomVision System . 189
KOMTRAX System . 191
System Diagram of KOMTRAX System . 191
Function of KOMTRAX System . 191
PPC Levers . 192
LH PPC Lever . 192
RH PPC Lever . 193
Automatic Grease System 194
Outline of AUTO Grease System 194
Component Parts of Control System 206
Machine Monitor 206
KomVision Controller . 220
KomVision Camera . 224
Gateway Function Controller 225
Communication Terminal . 228
Pump Controller 230
Resistor for PC-EPC Valve 234
CAN Terminating Resistor . 234
PPC Oil Pressure Switch 235
Engine Controller 236
Fuel Control Dial 242
Hydraulic System . 244
Layout Drawing of Hydraulic System . 244
CLSS . 250
Structure of CLSS 250
Operation of Unload Valve and LS Pressure 252
Pump Swash Plate Angle (Oil Flow) Control 253
Pressure Compensation Control 269
Engine and Pump Combined Control System 272
Engine and Pump Combined Control System Diagram 272
Function of Engine and Pump Combined Control System 273
Pump and Valve Control System 278
Pump and Valve Control System Diagram 278
Function of Pump and Valve Control System 279
Component Parts of Hydraulic System 281
Hydraulic Tank . 281
Main Pump 283
Pilot Oil Filter . 309
Control Valve 309
Work Equipment System 373
Layout Drawing of Work Equipment System 373
Structure of Valve Control . 378
One-Touch Power Maximizing System 380
System Diagram of One-Touch Power Maximizing System 380
Function of One-Touch Power Maximizing System 381
PPC Lock System 382
System Diagram of PPC Lock . 382
Function of PPC Lock System 382
Work Equipment and Travel Automatic Lock System 383
System Diagram of Lock Lever Automatic Lock System . 383
Function of Work Equipment and Travel Automatic Lock System 383
Operation of Lock Lever Automatic Lock System 384
Attachment Oil Flow Adjuster System 385
Attachment Oil Flow Adjuster System Diagram 385
Function of Attachment Oil Flow Adjuster System 386
Tool Control System 387
Tool Control System Diagram 387
Component Parts of Work Equipment System . 389
Work Equipment and Swing PPC Valve . 389
1st-Line Attachment PPC Valve (with EPC Valve) . 395
2nd-Line Attachment PPC Valve 401
Solenoid Valve . 403
Boom Anti-drop Valve . 406
Arm Anti-Drop Valve 410
Attachment Circuit Selector Valve (For High Pressure) 414
Attachment Circuit Selector Valve (For Low Pressure) . 416
Pilot Circuit Accumulator 419
Attachment Circuit Accumulator . 420
Swing System . 421
Layout Drawing of Swing System . 421
Swing Control System Diagram . 425
Function of Swing Control System . 425
Component Parts of Swing System 429
Swing Motor 429
Swing Machinery 440
Swing Circle . 441
Travel System 443
Layout Drawing of Travel System 443
System Diagram of Travel Control System 447
Function of Travel Control System 447
Component Parts of Travel System . 449
Travel Motor . 449
Final Drive 461
Travel PPC Valve . 463
Center Swivel Joint 468
Undercarriage and Frame 470
Layout Drawing of Undercarriage 470
Specifications of Undercarriage 471
Work Equipment . 472
Structure of Work Equipment 472
Function of Work Equipment . 473
Work Equipment Clearance Adjustment Shim . 474
Function of Work Equipment Clearance Adjustment Shim . 474
Bucket Clearance Adjustment Shim . 475
Function of Bucket Clearance Adjustment Shim . 475
CAB Related Parts 476
ROPS CAB . 476
Structure of ROPS CAB 476
Function of ROPS CAB . 476
CAB Mount 477
Structure of CAB Mount . 477
Function of CAB Mount 477
CAB Tipping Stopper 478
Structure of CAB Tipping Stopper . 478
Function of CAB Tipping Stopper 478
20 Standard Value Table 479
Table of Contents 480
Standard Value Table for Engine 481
Standard Value Table for Engine: PC210LC-11 481
Standard Value Table for Machine . 485
Standard Value Table for Machine: PC210LC-11 . 485
Machine Posture and Procedures to Measure Performance 498
Standard Value Table for Electricity . 502
Standard Value Table for Electricity . 502
30 Testing and Adjusting . 513
Table of Contents 514
Precautions Before Work 517
Related Information on Testing and Adjusting . 518
Tools for Testing and Adjusting 518
Sketch of Tools for Testing and Adjusting 525
Engine and Cooling System 527
Examine Engine Speed . 527
How to Examine Engine Speed 527
Examine Boost Pressure . 530
How to Examine Boost Pressure on Machine Monitor . 530
How to Examine Boost Pressure by Testing Tool 531
Examine Exhaust Gas Color 532
How to Examine Exhaust Gas Color with the Handy Smoke Checker 532
How to Examine Exhaust Gas Color with Smoke Meter 533
Examine Mass Air Flow and Temperature Sensor . 535
How to Examine Mass Air Flow and Temperature Sensor 535
Examine and Adjust Valve Clearance . 537
Check Valve Clearance 537
Adjust Valve Clearance . 538
Examine Compression Pressure . 540
How to Examine Compression Pressure 540
Examine Blowby Pressure 545
How to Examine Blowby Pressure . 545
Examine Engine Oil Pressure 547
How to Examine Engine Oil Pressure . 547
Examine EGR Valve and VGT Oil Pressure . 548
How to Examine EGR Valve and VGT Oil Pressure 548
Examine Fuel Pressure 550
How to Examine Fuel Pressure . 551
Examine Fuel Discharge, Return and Leakage . 556
How to Examine Fuel Discharge, Return, and Leakage . 557
Bleed Air from Fuel System . 563
How to Bleed Air from Fuel System 563
Examine Fuel Circuit for Leakage . 564
How to Examine Fuel System for Leakage . 564
Handle Cylinder Cut-out Mode Operation . 566
Handle No-Injection Cranking Operation . 567
Examine and Adjust Air Conditioner Compressor Belt Tension . 568
How to Examine Air Conditioner Compressor Belt . 568
How to Adjust Air Conditioner Compressor Belt 568
Examine Fan Belt and Alternator Belt . 570
How to Examine Fan Belt and Alternator Belt 570
Examine Automatic Tensioner 571
How to Examine Automatic Tensioner . 571
How to Replace Fan Belt 572
Examine Cooling Fan Speed 573
How to Examine Cooling Fan Speed . 573
Write Correction for Ash in Soot Accumulation to Engine Controller . 574
How to Write Correction for Ash in Soot Accumulation to Engine Controller 574
Examine SCR Related Functions 575
Examine DEF Pump Raised Pressure . 578
Examine Injection Volume from DEF Injector . 581
Examine DEF Line Heater Relay 1 584
Examine DEF Line Heater Relay 2 587
Examine DEF Pump Heater Relay 590
Examine DEF Tank Heater Valve 593
Examine SCR Denitration Efficiency . 596
Clean DEF Tank . 600
How to Clean DEF Tank 600
Clean DEF Pump . 604
How to Clean DEF Pump 604
Bleed Air from Coolant Circuit of DEF Tank . 611
How to Bleed Air from Coolant Circuit of DEF Tank 611
Power Train 613
Examine Swing Circle Bearing Clearance . 613
How to Examine Swing Circle Bearing Clearance 613
Undercarriage and Frame 614
Examine and Adjust Track Tension . 614
How to Examine Track Tension . 614
How to Adjust Track Tension 614
Hydraulic System . 616
Release Remained Pressure in Hydraulic Circuit . 616
How to Release Remained Pressure in Hydraulic System . 616
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 623
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 624
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . 630
Examine Oil Pressure of Control Circuit 633
Examine Oil Pressure in Control Circuit 633
Examine and adjust oil pressure in pump PC control circuit . 635
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) . 635
Examine PC-EPC Valve Outlet Pressure . 636
How to Adjust Oil Pressure in Pump PC Control Circuit 637
Examine and Adjust Oil Pressure in Pump LS Control Circuit . 639
Examine LS Differential Pressure with Machine Monitor 639
Examine LS Differential Pressure by Testing Tool . 640
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 643
How to Examine LS-EPC Valve Outlet Pressure 644
Adjust LS Valve 645
Examine Outlet Pressure of Solenoid Valve 646
How to Examine Outlet Pressure of Solenoid Valve . 646
Operating Condition of Solenoid Valve 647
Examine PPC Valve Outlet Pressure 650
Examine Outlet Pressure in PPC Valve . 650
Adjust Play of Work Equipment and Swing PPC Valves . 652
How to Adjust Play of Work Equipment and Swing PPC Valves 652
Measure and Adjust Quick Coupler Control Valve Output Pressure . 653
Examine Pump Swash Plate Sensor 655
How to Examine pump swash plate sensor . 655
Examine Parts Which Cause Hydraulic Drift of Work Equipment 656
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 656
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder . 656
How to Examine Parts that Cause Hydraulic Drift of PPC Valve . 657
Examine Oil Leakage 658
How to Examine Oil Leakage from Boom Cylinder 658
How to Examine Oil Leakage from Arm Cylinder . 658
How to Examine Oil Leakage from Bucket Cylinder 659
How to Examine Oil Leakage from Swing Motor 660
How to Examine Oil Leakage from Travel Motor . 660
Bleed Air from Hydraulic System 661
How to Bleed Air from Hydraulic System . 663
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 665
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) . 665
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) . 669
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 669
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 673
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping . 673
CAB Related Parts 680
Examine CAB Tipping Stopper 680
How to Examine Cab Tipping Stopper . 680
How to Adjust Mirrors 681
Procedure to Adjust Machine Left Front Mirror (A) 681
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 682
Procedure to Adjust Machine Right Front Mirror (B) . 683
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) . 684
Procedure to Adjust Machine Right Side Mirror (C) 685
Electrical System 687
Set and Operate Machine Monitor 687
Operator Mode 690
Function to Show Technician Identification Status Screen . 691
Function to Show Operator Identification Input Screen 691
Examine Function by LCD (Liquid Crystal Display) . 692
Examine Function of Service Meter 692
Usage Limitation and Maintenance Password Change Function 692
Service Mode . 695
How to Operate Service Mode 695
How to See Pre-defined Monitoring Information 697
How to Examine Self-Define Monitor Information . 704
Abnormality Record Menu 715
How to See Maintenance Record 719
Maintenance Mode Setting . 721
Set Phone Number Entry . 724
Default Menu . 725
Diagnostic Tests Menu 737
Adjustment Menu 746
No-Injection Cranking Operation 769
KOMTRAX Settings Menu 770
Show Service Message . 772
Start Up KOMTRAX System 774
Adjust Rearview Camera Angle . 779
How to Adjust Rearview Camera Angle 779
Adjust KomVision Camera Angle 782
How to Adjust KomVision Camera Angle . 783
Adjust KomVision Related Function 787
Setting of KomVision (Main Setting) 787
Setting of KomVision (Camera Setting) 789
Setting of KomVision (Camera Calibration) 791
KomVision screen – Check 12 m visibility . 804
Set Region of Bluetooth(R) Compatible Radio 807
Set Region of Bluetooth(R) Compatible Radio 807
Handle Voltage Circuit of Engine Controller 809
Handle Battery Isolator Switch . 810
Examine Diodes . 811
Examine Diodes by Digital Tester . 811
How to Examine Diodes by Analog Tester . 811
Pm Clinic 812
Pm Clinic Service 812
Pm Clinic Check Sheet 816
40 Troubleshooting . 829
Table of Contents 830
Precautions Before Work 841
Related Information to Troubleshooting . 842
General Troubleshooting Points . 842
Troubleshooting Points for Urea SCR System . 843
Sequence of Events in Troubleshooting 857
Checks Before Troubleshooting 859
Inspection Procedure Before Troubleshooting 861
Walk-Around Check 861
Test in Accordance with Testing Procedure 863
Examine Fuel Level and Type 863
Examine for Impure Ingredient in Fuel 863
Examine Fuel Prefilter . 864
Examine Water Separator, Drain Water and Sediment 864
How to Replace Fuel Prefilter Cartridge 865
Examine Fuel Main Filter . 866
Examine Engine Oil Level (Oil Quantity in Oil Pan) . 868
Examine Coolant Level (Reservoir Tank) . 869
Examine Air Cleaner Clogging . 869
Clean Outer Element 870
Replace Element 872
Examine Hydraulic Oil Level 873
Examine Hydraulic Oil Strainer . 874
Examine Hydraulic Oil Filter . 875
Examine Oil Level in Swing Machinery Case 876
Examine Oil Level in Damper Case . 877
Examine Oil Level in Final Drive Case 877
Bleed Air from Fuel System . 878
Bleed Air from Hydraulic System 878
How to Examine Electric Equipment 878
Automatic Grease System 886
Find Malfunctions 886
Malfunction Finding Procedures . 888
Preparation for Troubleshooting of Electrical System . 890
Procedure for Troubleshooting 903
Symptom and Troubleshooting Numbers 906
Information Shown in Troubleshooting Table . 910
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness . 912
Connector List and Layout 915
Connector Contact Connection Table . 928
T-Branch Box and T-Branch Adapter Table 968
Fuse Location Table 974
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 977
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) . 981
Failure Code Table . 983
Troubleshooting by Failure Code (Display of Code) 1003
Failure Code [6AZ0ZG] 1003
Failure Code [879AKA] 1005
Failure Code [879AKB] 1006
Failure Code [879BKA] 1007
Failure Code [879BKB] 1009
Failure Code [879CKA] 1011
Failure Code [879CKB] 1012
Failure Code [879DKZ] 1013
Failure Code [879EMC] 1015
Failure Code [879FMC] 1016
Failure Code [879GKX] 1017
Failure Code [989L00] 1019
Failure Code [989M00] 1020
Failure Code [989N00] 1021
Failure Code [A1U0N3] 1022
Failure Code [A1U0N4] 1024
Failure Code [A900FR] 1026
Failure Code [A900N6] 1027
Failure Code [A900NY] 1028
Failure Code [AA10NX] 1029
Failure Code [AB00KE] 1031
Failure Code [AQ10N3] 1034
Failure Code [AS00N3] 1036
Failure Code [AS00R2] 1038
Failure Code [AS00R3] 1039
Failure Code [AS00R4] 1040
Failure Code [AS00R5] 1041
Failure Code [AS00R6] 1042
Failure Code [AS00ZK] 1043
Failure Code [AS10KM] 1044
Failure Code [AS10NR] 1045
Failure Code [AS10NT] 1046
Failure Code [B@BAZG] 1047
Failure Code [B@BAZK] 1048
Failure Code [B@BCNS] 1050
Failure Code [B@BCQA] 1051
Failure Code [B@BCZK] 1053
Failure Code [B@HANS] 1055
Failure Code [CA115] .1056
Failure Code [CA122] .1057
Failure Code [CA123] .1059
Failure Code [CA131] .1061
Failure Code [CA132] .1063
Failure Code [CA144] .1065
Failure Code [CA145] .1067
Failure Code [CA153] .1069
Failure Code [CA154] .1072
Failure Code [CA187] .1074
Failure Code [CA221] .1076
Failure Code [CA222] .1078
Failure Code [CA227] .1080
Failure Code [CA234] .1081
Failure Code [CA238] .1082
Failure Code [CA239] .1084
Failure Code [CA249] .1086
Failure Code [CA256] .1088
Failure Code [CA271] .1090
Failure Code [CA272] .1092
Failure Code [CA322] .1094
Failure Code [CA323] .1096
Failure Code [CA324] .1098
Failure Code [CA325] .1100
Failure Code [CA331] .1102
Failure Code [CA332] .1104
Failure Code [CA343] .1106
Failure Code [CA351] .1107
Failure Code [CA352] .1108
Failure Code [CA356] .1111
Failure Code [CA357] .1113
Failure Code [CA386] .1115
Failure Code [CA428] .1116
Failure Code [CA429] .1118
Failure Code [CA435] .1120
Failure Code [CA441] .1122
Failure Code [CA442] .1125
Failure Code [CA449] .1126
Failure Code [CA451] .1127
Failure Code [CA452] .1129
Failure Code [CA488] .1131
Failure Code [CA515] .1132
Failure Code [CA516] .1134
Failure Code [CA553] .1136
Failure Code [CA555] .1137
Failure Code [CA556] .1138
Failure Code [CA559] .1139
Failure Code [CA595] .1142
Failure Code [CA687] .1143
Failure Code [CA689] .1145
Failure Code [CA691] .1148
Failure Code [CA692] .1150
Failure Code [CA697] .1152
Failure Code [CA698] .1153
Failure Code [CA731] .1154
Failure Code [CA778] .1156
Failure Code [CA1117] 1161
Failure Code [CA1664] 1162
Failure Code [CA1669] 1164
Failure Code [CA1673] 1165
Failure Code [CA1677] 1166
Failure Code [CA1678] 1167
Failure Code [CA1682] 1168
Failure Code [CA1683] 1170
Failure Code [CA1684] 1172
Failure Code [CA1686] 1174
Failure Code [CA1691] 1175
Failure Code [CA1694] 1178
Failure Code [CA1695] 1181
Failure Code [CA1696] 1182
Failure Code [CA1712] 1184
Failure Code [CA1713] 1187
Failure Code [CA1714] 1189
Failure Code [CA1715] 1190
Failure Code [CA1776] 1191
Failure Code [CA1777] 1194
Failure Code [CA1843] 1197
Failure Code [CA1844] 1199
Failure Code [CA1879] 1202
Failure Code [CA1881] 1204
Failure Code [CA1883] 1206
Failure Code [CA1885] 1209
Failure Code [CA1887] 1211
Failure Code [CA1921] 1213
Failure Code [CA1922] 1216
Failure Code [CA1942] 1221
Failure Code [CA1993] 1222
Failure Code [CA2185] 1225
Failure Code [CA2186] 1226
Failure Code [CA2249] 1228
Failure Code [CA2271] 1229
Failure Code [CA2272] 1232
Failure Code [CA2288] 1235
Failure Code [CA2311] 1236
Failure Code [CA2349] 1237
Failure Code [CA2353] 1240
Failure Code [CA2357] 1242
Failure Code [CA2381] 1243
Failure Code [CA2382] 1246
Failure Code [CA2383] 1249
Failure Code [CA2386] 1252
Failure Code [CA2387] 1254
Troubleshooting Flowchart 1258
Failure Code [CA2555] 1259
Failure Code [CA2556] 1262
Failure Code [CA2637] 1265
Failure Code [CA2639] 1267
Failure Code [CA2771] 1270
Failure Code [CA2777] 1276
Failure Code [CA2976] 1279
Failure Code [CA3133] 1281
Failure Code [CA3134] 1284
Failure Code [CA3135] 1286
Failure Code [CA3142] 1289
Failure Code [CA3143] 1290
Failure Code [CA3144] 1291
Failure Code [CA3146] 1293
Failure Code [CA3147] 1294
Failure Code [CA3148] 1295
Failure Code [CA3151] 1297
Failure Code [CA3165] 1303
Failure Code [CA3229] 1305
Failure Code [CA3231] 1307
Failure Code [CA3232] 1309
Failure Code [CA3235] 1313
Failure Code [CA3239] 1315
Failure Code [CA3241] 1318
Failure Code [CA3242] 1321
Failure Code [CA3251] 1324
Failure Code [CA3253] 1326
Failure Code [CA3254] 1329
Failure Code [CA3255] 1332
Failure Code [CA3256] 1336
Failure Code [CA3311] 1338
Failure Code [CA3312] 1340
Failure Code [CA3313] 1343
Failure Code [CA3314] 1344
Failure Code [CA3315] 1345
Failure Code [CA3316] 1347
Failure Code [CA3317] 1348
Failure Code [CA3318] 1349
Failure Code [CA3319] 1351
Failure Code [CA3321] 1352
Failure Code [CA3322] 1354
Failure Code [CA3419] 1356
Failure Code [CA3421] 1358
Failure Code [CA3497] 1360
Failure Code [CA3498] 1361
Failure Code [CA3543] 1362
Failure Code [CA3545] 1369
Failure Code [CA3547] 1371
Failure Code [CA3558] 1372
Failure Code [CA3559] 1374
Failure Code [CA3562] 1376
Failure Code [CA3563] 1378
Failure Code [CA3567] 1381
Failure Code [CA3568] 1384
Failure Code [CA3571] 1388
Failure Code [CA3572] 1390
Failure Code [CA3574] 1392
Failure Code [CA3575] 1394
Failure Code [CA3577] 1396
Failure Code [CA3578] 1398
Failure Code [CA3582] 1400
Failure Code [CA3583] 1406
Failure Code [CA3596] 1408
Failure Code [CA3649] 1410
Failure Code [CA3681] 1412
Failure Code [CA3682] 1417
Failure Code [CA3713] 1422
Failure Code [CA3717] 1425
Failure Code [CA3718] 1426
Failure Code [CA3725] 1427
Failure Code [CA3741] 1430
Failure Code [CA3748] 1431
Failure Code [CA3751] 1433
Failure Code [CA3755] 1435
Failure Code [CA3866] 1437
Failure Code [CA3867] 1441
Failure Code [CA3868] 1444
Failure Code [CA3899] 1448
Failure Code [CA3911] 1450
Failure Code [CA3912] 1454
Failure Code [CA3932] 1456
Failure Code [CA3933] 1458
Failure Code [CA3934] 1460
Failure Code [CA3935] 1463
Failure Code [CA3936] 1465
Failure Code [CA4151] 1467
Failure Code [CA4152] 1471
Failure Code [CA4155] 1475
Failure Code [CA4156] 1478
Failure Code [CA4157] 1481
Failure Code [CA4158] 1483
Failure Code [CA4159] 1484
Failure Code [CA4161] 1485
Failure Code [CA4162] 1488
Failure Code [CA4163] 1491
Failure Code [CA4164] 1492
Failure Code [CA4165] 1494
Failure Code [CA4166] 1496
Failure Code [CA4168] 1497
Failure Code [CA4169] 1500
Failure Code [CA4171] 1502
Failure Code [CA4249] 1505
Failure Code [CA4251] 1507
Failure Code [CA4259] 1509
Failure Code [CA4261] 1512
Failure Code [CA4277] 1515
Failure Code [CA4281] 1518
Failure Code [CA4459] 1521
Failure Code [CA4461] 1524
Failure Code [CA4658] 1527
Failure Code [CA4731] 1531
Failure Code [CA4732] 1532
Failure Code [CA4739] 1533
Failure Code [CA4768] 1534
Failure Code [CA4769] 1536
Failure Code [CA4842] 1539
Failure Code [CA4952] 1543
Failure Code [CA5115] 1545
Failure Code [CA5179] 1548
Failure Code [CA5181] 1550
Failure Code [CA5383] 1552
Failure Code [D110KB] 1554
Failure Code [D19JKZ] 1556
Failure Code [D811MC] 1559
Failure Code [D862KA] 1560
Failure Code [D8ALKA] 1562
Failure Code [D8ALKB] 1565
Failure Code [D8AQKR] 1567
Failure Code [D8G1KT] 1574
Failure Code [D8G6KT] 1575
Failure Code [DA20MC] 1576
Failure Code [DA22KK] 1577
Failure Code [DA25KP] 1580
Failure Code [DA26KP] 1583
Failure Code [DA29KQ] 1585
Failure Code [DA2LKA] 1587
Failure Code [DA2LKB] 1590
Failure Code [DA2QKR] 1592
Failure Code [DA2RKR] 1601
Failure Code [DAF0KM] 1602
Failure Code [DAF0MB] 1603
Failure Code [DAF0MC] 1604
Failure Code [DAF8KB] 1605
Failure Code [DAF9KQ] 1609
Failure Code [DAFGMC] 1610
Failure Code [DAFLKA] 1611
Failure Code [DAFLKB] 1614
Failure Code [DAFQKR] 1616
Failure Code [DAZ9KQ] 1624
Failure Code [DAZQKR] 1625
Failure Code [DB2QKR] 1632
Failure Code [DB2RKR] 1640
Failure Code [DBP0KM] 1645
Failure Code [DBP0KT] 1646
Failure Code [DBP5KB] 1647
Failure Code [DBP5KY] 1650
Failure Code [DBPQKR] 1652
Failure Code [DDNRKA] 1660
Failure Code [DDNRKY] 1662
Failure Code [DDNS00] 1664
Failure Code [DFB1KZ] 1666
Failure Code [DFB2KZ] 1668
Failure Code [DFB3L8] 1670
Failure Code [DFB4L8] 1672
Failure Code [DFB5KZ] 1674
Failure Code [DFB6KZ] 1676
Failure Code [DGH2KA] 1678
Failure Code [DGH2KB] 1680
Failure Code [DHA4KA] 1682
Failure Code [DHAAMA] 1684
Failure Code [DHACMA] 1686
Failure Code [DHPAMA] 1688
Failure Code [DHPBMA] 1691
Failure Code [DHS3MA] 1694
Failure Code [DHS4MA] 1697
Failure Code [DHS8MA] 1700
Failure Code [DHS9MA] 1703
Failure Code [DHSAMA] 1706
Failure Code [DHSBMA] 1709
Failure Code [DHSCMA] 1712
Failure Code [DHSDMA] 1715
Failure Code [DHSFMA] 1718
Failure Code [DHSGMA] 1721
Failure Code [DHSHMA] 1724
Failure Code [DHSJMA] 1727
Failure Code [DHX1MA] 1730
Failure Code [DHZAMA] 1732
Failure Code [DHZCL8] 1736
Failure Code [DKR0MA] 1737
Failure Code [DKR1MA] 1740
Failure Code [DKULKA] 1743
Failure Code [DKULKB] 1745
Failure Code [DKULKY] 1747
Failure Code [DLM5KA] 1749
Failure Code [DLM5MB] 1751
Failure Code [DR10KA] 1753
Failure Code [DR12KA] 1756
Failure Code [DR20KA] 1758
Failure Code [DR21KX] 1760
Failure Code [DR30KA] 1762
Failure Code [DR31KX] 1764
Failure Code [DR40KA] 1766
Failure Code [DUMBKA] 1768
Failure Code [DUMBKB] 1771
Failure Code [DV20KB] 1773
Failure Code [DW43KA] 1775
Failure Code [DW43KB] 1777
Failure Code [DW43KY] 1779
Failure Code [DW45KA] 1781
Failure Code [DW45KB] 1784
Failure Code [DW45KY] 1787
Failure Code [DW4CKY] 1789
Failure Code [DW91KA] 1791
Failure Code [DW91KB] 1793
Failure Code [DW91KY] 1795
Failure Code [DWA2KA] 1797
Failure Code [DWA2KB] 1799
Failure Code [DWA2KY] 1801
Failure Code [DWK0KA] 1803
Failure Code [DWK0KB] 1805
Failure Code [DWK0KY] 1807
Failure Code [DWK2KA] 1809
Failure Code [DWK2KB] 1811
Failure Code [DWK2KY] 1813
Failure Code [DWK8KA] 1815
Failure Code [DWK8KB] 1817
Failure Code [DWK8KY] 1819
Failure Code [DWN5KA] 1821
Failure Code [DWN5KB] 1823
Failure Code [DWN5KY] 1825
Failure Code [DWPUKA] 1827
Failure Code [DWPUKB] 1829
Failure Code [DWPUKY] 1831
Failure Code [DXA8KA] 1833
Failure Code [DXA8KB] 1835
Failure Code [DXA9KA] 1837
Failure Code [DXA9KB] 1839
Failure Code [DXE0KA] 1841
Failure Code [DXE0KB] 1843
Failure Code [DXE4KA] 1845
Failure Code [DXE4KB] 1847
Failure Code [DXE4KY] 1849
Failure Code [DXE5KA] 1851
Failure Code [DXE5KB] 1853
Failure Code [DXE6KA] 1855
Failure Code [DXE6KB] 1857
Failure Code [DXE7KA] 1859
Failure Code [DXE7KB] 1861
Failure Code [DXE7KY] 1863
Failure Code [DXE8KA] 1865
Failure Code [DXE8KB] 1867
Failure Code [DXE8KY] 1869
Failure Code [DXE9KA] 1871
Failure Code [DXE9KB] 1873
Failure Code [DXE9KY] 1875
Failure Code [DXEAKA] 1877
Failure Code [DXEAKB] 1879
Failure Code [DXEAKY] 1881
Failure Code [DXEKKA] 1883
Failure Code [DXEKKB] 1885
Failure Code [DXEKKY] 1887
Failure Code [DXELKA] 1889
Failure Code [DXELKB] 1891
Failure Code [DXELKY] 1893
Failure Code [DY20KA] 1895
Failure Code [DY20MA] 1897
Failure Code [DY2CKB] 1899
Failure Code [DY2DKB] 1902
Failure Code [DY2EKB] 1904
Failure Code [F311KA] 1906
Failure Code [F311KB] 1908
Failure Code [F312KA] 1910
Failure Code [F312KB] 1912
Failure Code [F313KA] 1914
Failure Code [F313KB] 1916
Failure Code [F314KA] 1919
Failure Code [F314KB] 1921
Failure Code [F315KB] 1923
Failure Code [F315KY] 1925
Failure Code [F316KB] 1927
Failure Code [F316KY] 1929
Failure Code [F318KB] 1931
Failure Code [F318KY] 1934
Failure Code [F31AKB] 1936
Failure Code [F31AKY] 1938
Failure Code [F31BKB] 1940
Failure Code [F31BKY] 1942
Failure Code [F31CKB] 1944
Failure Code [F31CKY] 1946
Failure Code [F31DKB] 1948
Failure Code [F31DKY] 1950
Failure Code [F31EKB] 1952
Failure Code [F31EKY] 1954
Troubleshooting of Electrical System (E-Mode) 1956
E-1 Engine Does Not Start (Engine Does Not Crank) 1956
E-2 Manual Preheating System Does Not Operate 1962
E-3 Automatic Preheating System Does Not Operate .1965
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1967
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing .1969
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1972
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1973
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation .1974
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1975
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs .1976
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation .1977
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1978
E-13 Water Separator Monitor Comes On in Red While Engine Runs .1979
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1980
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1981
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1982
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1983
E-18 Display of Fuel Gauge is Different from Actual Fuel Level .1985
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum .1986
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature .1987
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum .1988
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature .1990
E-23 Some Areas of Machine Monitor Screen are Not Shown 1991
E-24 Function Switch Does Not Operate 1992
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1993
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1994
E-27 Auto-Decelerator is Not Operated or Canceled with Lever .1995
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1996
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed .1997
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1998
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change .1999
E-32 Alarm Buzzer Cannot be Canceled .2001
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 2002
E-34 Service Mode Cannot be Selected .2003
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 2004
E-36 All Work Equipment, Swing and Travel Do Not Lock 2007
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 2009
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 2012
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show .2014
E-40 One-Touch Power Maximizing Function is Not Cancelled 2017
E-41 Alarm Does Not Sound During Travel 2018
E-42 Alarm Does Not Stop When Machine Stops 2020
E-43 Horn Does Not Sound .2021
E-44 Horn Does Not Stop 2024
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out .2026
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2027
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 2029
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2030
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2031
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function .2032
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 2033
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function .2034
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function .2035
E-54 “Swing” is Not Shown Correctly with Monitoring Function .2036
E-55 “Travel” is Not Shown Correctly with Monitoring Function 2037
E-56 Service is Not Shown Correctly with Monitoring Function .2038
E-57 Attachment Hydraulic Circuit Cannot be Changed 2040
E-58 KOMTRAX System Does Not Operate Correctly .2041
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2042
Information Shown in Troubleshooting Table (H-Mode) 2042
System Chart of Hydraulic and Mechanical Systems .2043
Failure Mode and Cause Table .2045
H-1 All Work Equipment, Swing and Travel Do Not Work .2054
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2055
H-3 Fine Control Performance or Response is Unsatisfactory .2058
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2059
H-5 Engine Speed Drops Largely or Engine Stops .2060
H-6 Speed or Power of Boom is Low 2062
H-7 Arm Speed or Power is Low 2066
H-8 Bucket Speed or Power is Low .2071
H-9 Work Equipment Does Not Move in Single Operation .2074
H-10 Hydraulic Drift of Boom is Large 2075
H-11 Hydraulic Drift of Arm is Large .2077
H-12 Hydraulic Drift of Bucket is Large 2079
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2080
H-14 Time Lag of Work Equipment is Large .2081
H-15 One-Touch Power Maximizing Function Does Not Operate 2082
H-16 Attachment Circuit Cannot be Changed 2083
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2084
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower .2085
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2086
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low .2087
H-21 Machine Does Not Travel Straight 2088
H-22 Machine is Not Steered Correctly or Steering Power is Low .2090
H-23 Travel Speed is Low .2093
H-24 One of Tracks Does Not Run 2095
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast .2096
H-26 Upper Structure Does Not Swing to Right and Left 2097
H-27 Upper Structure Swings Only to Right or Left 2098
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions .2099
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2100
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2101
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2102
H-32 Shock is Large When Upper Structure Stops Swing Operation .2103
H-33 There is Large Unusual Noise When It Stops Swing Operation 2104
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2105
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) .2106
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2107
H-37 Unusual Noise is Heard from Around Fan 2108
H-38 Quick coupler cylinder will not extend 2109
H-39 Quick coupler cylinder will not retract (but buzzer does not sound) .2111
H-40 Buzzer Does Not Operate (but Quick Coupler Cylinder Does Retract) .2113
H-41 Quick coupler cylinder extends and retracts slowly 2114
Troubleshooting of Engine (S-Mode) .2115
Information Shown in Troubleshooting Table (S-Mode) 2115
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position .2116
S-2 Engine Cranks but No Exhaust Smoke Comes Out .2117
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2118
S-4 Engine Startability is Unsatisfactory 2120
S-5 Engine Does Not Pick Up Smoothly .2122
S-6 Engine Stops During Operation 2124
S-7 Engine Runs Rough or is Not Stable .2126
S-8 Engine Lacks Power .2127
S-9 KDPF Becomes Clogged in a Short Time .2129
S-10 Engine Oil Consumption is Excessive .2131
S-11 Oil Becomes Dirty Quickly .2132
S-12 Fuel Consumption is Excessive .2133
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2134
S-14 Oil Pressure Drops 2135
S-15 Fuel Mixes Into Engine Oil 2137
S-16 Water Mixes Into Engine Oil (Milky) .2138
S-17 Coolant Temperature Increases Too High (Overheating) 2139
S-18 Unusual Noise is Heard 2140
S-19 Vibration is Excessive 2141
S-20 Air Cannot be Bled from Fuel Circuit 2142
S-21 Active Regeneration is Done Frequently 2143
S-22 Active Regeneration Continues Long 2145
S-23 White Smoke is Exhausted During Active Regeneration .2146
S-24 DEF Consumption is Excessive 2147
S-25 There is Unusual Smell (Irritating Odor) 2149
S-26 Foreign Materials Enter DEF (DEF Increases) .2150
50 Disassembly and Assembly 2151
Table of Contents 2152
Precautions Before Work 2157
Related Information on Disassembly and Assembly 2158
How to Read This Manual 2158
Coating Materials List .2159
Special Tool List 2164
Sketches of Special Tools 2176
Engine and Cooling System 2182
Remove and Install Supply Pump Assembly 2182
Remove Supply Pump Assembly 2182
Install Supply Pump Assembly .2185
Remove and Install Injector Assembly .2188
How to Remove Injector Assembly 2188
How to Install Injector Assembly .2193
Remove and Install Cylinder Head Assembly 2201
How to Remove Cylinder Head Assembly .2202
How to Install Cylinder Head Assembly 2211
Remove and Install EGR Valve Assembly 2227
Remove EGR Valve Assembly 2227
Install EGR Valve Assembly .2228
Remove and Install EGR Cooler Assembly .2230
How to Remove EGR Cooler Assembly 2230
How to Install EGR Cooler Assembly .2234
Remove and Install Starter Assembly 2239
Remove Starting Motor Assembly .2239
Install Starting Motor Assembly 2240
Remove and Install Alternator Belt .2243
Remove Alternator Belt .2243
Install Alternator Belt 2245
Remove and Install Radiator Assembly .2248
How to Remove Radiator Assembly 2248
How to Install Radiator Assembly .2250
Remove and Install Hydraulic Oil Cooler Assembly .2253
How to Remove Hydraulic Oil Cooler Assembly 2253
How to Install Hydraulic Oil Cooler Assembly .2256
Remove and Install Aftercooler Assembly 2259
Remove Aftercooler Assembly 2259
Install Aftercooler Assembly .2261
Remove and Install Fan Clutch Assembly .2263
How to Remove Fan Clutch Assembly 2263
How to Install Fan Clutch Assembly .2268
Remove and Install Fan .2272
Remove Fan .2272
Install Fan 2272
Remove and Install Engine and Main Pump Assembly .2273
Remove Engine and Main Pump Assembly .2273
Install Engine and Main Pump Assembly 2282
Remove and Install Engine Front Oil Seal .2294
How to Remove Engine Front Oil Seal 2294
How to Install Engine Front Oil Seal .2297
Remove and Install Engine Rear Oil Seal 2301
How to Remove Engine Rear Oil Seal .2301
How to Install Engine Rear Oil Seal 2302
Remove and Install Fuel Cooler Assembly 2305
Remove Fuel Cooler Assembly 2305
Install Fuel Cooler Assembly .2305
Remove and Install Engine Hood Assembly 2307
How to Remove Engine Hood Assembly .2307
How to Install Engine Hood Assembly 2309
Remove and Install Fuel Tank Assembly 2314
Remove Fuel Tank Assembly 2314
Install Fuel Tank Assembly .2318
Remove and Install DEF Tank Assembly .2324
How to Remove DEF Tank Assembly 2324
How to Install DEF Tank Assembly .2329
Remove and Install DEF Tank Sensor Flange Assembly .2335
How to Remove DEF Tank Sensor Flange Assembly 2335
How to Install DEF Tank Sensor Flange Assembly .2341
Remove and Install DEF Tank Sensor .2347
Remove DEF Tank Sensor .2347
Install DEF Tank Sensor 2347
Remove and Install DEF Tank Strainer .2354
Remove DEF Tank Strainer .2354
Install DEF Tank Strainer 2354
Remove and Install DEF Tank Filler Port Filter .2355
Remove DEF Tank Filler Port Filter .2355
Install DEF Tank Filler Port Filter 2357
Remove and Install KDPF Assembly .2360
How to Remove KDPF Assembly 2360
How to Install KDPF Assembly .2362
Disassemble and Assemble KDPF Assembly .2364
Disassemble KDPF Assembly 2365
Assemble KDPF Assembly .2368
Remove and Install SCR Assembly 2373
How to Remove SCR Assembly .2373
How to Install SCR Assembly 2375
Remove and Install KDPF and SCR Assembly .2377
How to Remove KDPF and SCR Assembly 2377
Install KDPF and SCR Assembly 2384
Remove and Install KDPF and SCR Assembly Bracket .2390
Remove KDPF and SCR Assembly Bracket .2390
Install KDPF and SCR Assembly Bracket 2397
Remove and Install Bellows Pipe Assembly .2404
How to Remove Bellows Pipe Assembly 2404
How to Install Bellows Pipe Assembly .2406
Remove and Install KCCV Assembly .2410
Remove KCCV Assembly .2410
Install KCCV Assembly 2412
Remove and Install DEF Mixing Tube .2417
Remove DEF Mixing Tube .2417
Install DEF Mixing Tube 2423
Remove and Install DEF Injector 2429
Remove DEF Injector 2429
Install DEF Injector .2432
Remove and Install DEF Pump 2435
Remove DEF Pump 2435
Install DEF Pump .2438
Remove and Install DEF Hose 2441
Remove DEF Hose 2441
Install DEF Hose .2449
Remove and Install Air Cleaner Assembly 2455
Remove Air Cleaner Assembly 2455
Install Air Cleaner Assembly .2456
Remove and Install Air Conditioner Compressor Assembly .2458
Remove Air Conditioner Compressor Assembly .2458
How to Install Air Conditioner Compressor Assembly .2460
Remove and Install Air Conditioner Condenser Assembly 2463
How to Remove Air Conditioner Condenser Assembly .2463
How to Install Air Conditioner Condenser Assembly 2464
Power Train 2465
Remove and Install Travel Motor and Final Drive Assembly .2465
Remove Travel Motor and Final Drive Assembly .2465
Install Travel Motor and Final Drive Assembly 2466
Disassemble and Assemble Final Drive Assembly 2468
Disassemble Final Drive Assembly .2468
Assemble Final Drive Assembly 2472
Remove and Install Swing Motor and Swing Machinery Assembly 2481
Remove Swing Motor and Swing Machinery Assembly 2481
Install Swing Motor and Swing Machinery Assembly .2483
Disassemble and Assemble Swing Machinery Assembly 2487
Disassemble Swing Machinery Assembly .2487
Assemble Swing Machinery Assembly 2491
Remove and Install Swing Circle Assembly .2498
Remove Swing Circle Assembly .2498
Install Swing Circle Assembly 2498
Undercarriage and Frame 2500
Separate and Connect Track Assembly 2500
Separate Track Assembly 2500
Install Track Assembly .2502
Remove and Install Sprocket 2505
Remove Sprocket 2505
Install Sprocket .2505
Remove and Install Idler and Idler Cushion Assembly 2507
Remove Idler and Idler Cushion Assembly 2507
Install Idler and Idler Cushion Assembly .2508
Disassemble and Assemble Idler Assembly 2509
Disassemble Idler Assembly .2509
Assemble Idler Assembly 2510
Disassemble and Assemble Idler Cushion Assembly 2514
Disassemble Idler Cushion Assembly .2515
Assemble Idler Cushion Assembly 2515
Disassemble and Assemble Track Roller Assembly .2517
Disassemble Track Roller Assembly 2518
Assemble Track Roller Assembly .2519
Disassemble and Assemble Carrier Roller Assembly .2521
Disassemble Carrier Roller Assembly 2521
Assemble Carrier Roller Assembly .2523
Remove and Install Revolving Frame Assembly 2525
Remove Revolving Frame Assembly 2525
Install Revolving Frame Assembly .2527
Remove and Install Counterweight Assembly 2530
Remove Counterweight Assembly 2530
Install Counterweight Assembly .2533
Hydraulic System .2537
Remove and Install Center Swivel Joint Assembly 2537
Remove Center Swivel Joint Assembly 2537
Install Center Swivel Joint Assembly .2539
Disassemble and Assemble Center Swivel Joint Assembly 2542
Disassemble Center Swivel Joint Assembly .2542
Assemble Center Swivel Joint Assembly 2543
Remove and Install Hydraulic Tank Assembly .2545
Remove Hydraulic Tank Assembly .2545
How to Install Hydraulic Tank Assembly .2548
Remove and Install Main Pump Assembly 2552
Remove Main Pump Assembly 2552
Install Main Pump Assembly .2555
Remove and Install Control Valve Assembly 2559
How to Remove Control Valve Assembly .2559
How to Install Control Valve Assembly 2566
Disassemble and Assemble Control Valve Assembly 2574
Replace Pressure Compensation Valve Seal Ring 2574
Assemble Control Valve Assembly 2576
Disassemble and Assemble Work Equipment PPC Valve Assembly .2580
Disassemble Work Equipment PPC Valve Assembly 2580
How to Assemble Work Equipment PPC Valve Assembly 2580
Disassemble and Assemble Travel PPC Valve Assembly .2582
Disassemble Travel PPC Valve Assembly 2582
How to Assemble Travel PPC Valve Assembly 2583
Work Equipment .2585
Remove and Install Work Equipment Assembly .2585
Remove Work Equipment Assembly .2585
Install Work Equipment Assembly 2589
Remove and Install Boom Anti-drop Valve Assembly .2594
Remove Boom Anti-drop Valve Assembly .2594
Install Boom Anti-drop Valve Assembly 2596
Remove and Install Arm Anti-Drop Valve Assembly 2597
Remove Arm Anti-Drop Valve Assembly 2597
Install Arm Anti-Drop Valve Assembly .2599
Disassemble and Assemble Anti-Drop Valve Assembly 2600
Disassemble Anti-Drop Valve Assembly .2600
Assemble Anti-Drop Valve Assembly 2600
Disassemble and Assemble Work Equipment Cylinder Assembly 2601
How to Disassemble Work Equipment Cylinder Assembly 2601
How to Assemble Work Equipment Cylinder Assembly .2604
CAB Related Parts 2610
Remove and Install Operator Cab Assembly .2610
How to Remove Operator Cab Assembly 2610
Install Operator CAB Assembly 2618
Remove and Install Operator Cab Glass (Adhered Glass) 2625
Remove Operator CAB Glass (Adhered Glass) 2627
Install Operator CAB Glass (Adhered Glass) .2627
Remove and Install Front Window Assembly .2637
Remove Front Window Assembly .2637
Install Front Window Assembly 2640
Remove and Install Floor Frame Assembly 2646
How to Remove Floor Frame Assembly .2646
How to Install Floor Frame Assembly 2653
Remove and Install Air Conditioner Unit Assembly .2660
Remove Air Conditioner Unit Assembly .2660
Install Air Conditioner Unit Assembly 2666
Remove and Install Operator Seat .2673
Remove Operator’s Seat .2673
Install Operator’s Seat 2675
How to Remove and Install Seat Belt 2678
How to Remove Seat Belt 2678
How to Install Seatbelt 2679
Remove and Install Work Equipment Control Lever Assembly .2680
How to Remove Work Equipment Control Lever Assembly 2680
How to Install Work Equipment Control Lever Assembly .2686
Remove and Install Front Wiper Assembly 2695
Remove Front Wiper Assembly 2695
Install Front Wiper Assembly .2700
Electrical System 2709
Remove and Install Engine Controller Assembly 2709
Remove Engine Controller Assembly 2709
Install Engine Controller Assembly .2711
Remove and Install Pump Controller Assembly 2712
Remove Pump Controller Assembly 2712
Install Pump Controller Assembly .2716
Remove and Install KomVision Controller Assembly .2721
Remove KomVision Controller Assembly .2721
Install KomVision Controller Assembly 2722
Remove and Install Machine Monitor Assembly 2724
Remove Machine Monitor Assembly 2724
Install Machine Monitor Assembly .2727
Remove and Install Pump Swash Plate Sensor .2731
Remove Pump Swash Plate Sensor .2731
Install Pump Swash Plate Sensor 2732
Remove and Install Mass Air Flow and Temperature Sensor 2733
How to Remove Mass Air Flow and Temperature Sensor .2733
How to Install Mass Air Flow and Temperature Sensor 2733
Remove and Install KCCV Crankcase Pressure Sensor 2735
How to Remove KCCV Crankcase Pressure Sensor .2735
How to Install KCCV Crankcase Pressure Sensor 2736
Remove and Install SCR Temperature Sensor 2737
Remove SCR Temperature Sensor 2737
Install SCR Temperature Sensor .2739
Remove and Install KomVision Camera 2742
Remove KomVision Camera 2742
Install KomVision Camera .2745
Remove and Install Gateway Function Controller Assembly 2748
Remove Gateway Function Controller Assembly 2748
How to Install Gateway Function Controller Assembly 2753
Remove and Install Communication Terminal Wiring Harness .2758
Remove Communication Terminal Wiring Harness .2758
Install Communication Terminal Wiring Harness 2766
Remove and Install Communication Terminal 2775
Remove Communication Terminal 2775
Install Communication Terminal .2777
60 Maintenance Standard 2781
Table of Contents 2782
Engine and Cooling System 2783
Maintenance Standard for Engine Mount 2783
Maintenance Standard for Cooling System 2784
Power Train 2786
Maintenance Standard for Swing Circle 2786
Maintenance Standard for Swing Machinery .2787
Maintenance Standard for Final Drive .2789
Maintenance Standard for Sprocket 2791
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing .2792
Undercarriage and Frame 2793
Maintenance Standard for Track Frame and Idler Cushion .2793
Maintenance Standard for Idler .2795
Maintenance Standard for Track Roller 2797
Maintenance Standard for Carrier Roller 2798
Maintenance Standard for Track Shoes .2799
Maintenance Standard for Triple Shoes 2802
Maintenance Standard for Swamp Shoes .2803
Maintenance Standard for Road Liner 2804
Hydraulic System .2805
Maintenance Standard for Hydraulic Tank 2805
Maintenance Standard for Main Pump .2806
Maintenance Standard for LS-EPC Valve 2807
Maintenance Standard for PC-EPC Valve 2808
Maintenance Standard for Swing Motor .2809
Maintenance Standard for Travel Motor 2812
Maintenance Standard for Control Valve .2815
Maintenance Standard for Boom Anti-Drop Valve 2825
Maintenance Standard for Arm Anti-Drop Valve .2827
Maintenance Standard for Work Equipment and Swing PPC Valve 2829
Maintenance Standard for Travel PPC Valve 2832
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2835
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2836
Maintenance Standard for 2nd-Line Attachment PPC Valve .2838
Maintenance Standard for Solenoid Valve 2840
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) .2841
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2842
Maintenance Standard for Center Swivel Joint .2843
Work Equipment .2844
Maintenance Standard for Work Equipment Linkage 2844
Dimensions of Arm 2849
Dimensions of Bucket .2851
Maintenance Standard for Boom Cylinder (Large Diameter Piston) .2853
Maintenance Standard for Arm Cylinder 2854
Maintenance Standard for Bucket Cylinder .2855
80 Appendix 2857
Table of Contents 2858
Precautions Before Work 2860
Air Conditioner System .2861
Precautions for Refrigerant 2861
Air Conditioner Component 2862
Specifications of Air Conditioner 2864
Structure and Function of Refrigeration Cycle 2865
Outline of Refrigeration Cycle .2866
Component Parts of Air Conditioner System 2868
Air Conditioner Unit .2868
Configuration Diagram of Air Conditioner Unit 2868
Function of Air Conditioner Unit .2870
Component Parts of Air Conditioner Unit 2872
Function of Evaporator as Air Conditioner Unit Component .2873
Function of Heater Core as Air Conditioner Unit Component 2873
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2873
Function of Servo Motor as Air Conditioner Unit Component 2873
Structure of Expansion Valve as Air Conditioner Unit Component .2874
Function of Expansion Valve as Air Conditioner Unit Component 2874
Operate Expansion Valve as Air Conditioner Unit Component 2874
Function of Dual Pressure Switch .2875
Air Conditioner Controller .2876
Structure of Air Conditioner Controller 2876
Compressor .2877
Structure of Compressor 2877
Specifications of Compressor .2877
Function of Compressor .2877
Condenser 2878
Structure of Condenser .2878
Specifications of Condenser 2878
Function of Condenser 2878
Air Conditioner Related Sensors 2880
Structure of Sunlight Sensor .2880
Function of Sunlight Sensor 2880
Structure of Outside Temperature Sensor 2880
Function of Outside Air Temperature Sensor .2880
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2882
Circuit Diagram and Configuration of Connector Pins of Air Conditioner .2884
System Diagram of Air Conditioner 2886
Input and Output Signals of Air Conditioner Controller .2887
Function of Air Conditioner Controller .2888
Locations of Air Conditioner Parts and Layout of Connectors 2889
Examine Air Leakage (Duct) .2893
How to Examine Air Leakage (Duct) 2893
Examine Air Conditioner with Self-Diagnosis Function .2895
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2896
Examine Vent (Mode) Changeover .2897
How to Examine Vent (Mode) Changeover 2897
Examine Fresh/Recirc Air Changeover 2899
How to Examine Fresh/Recirc Air Changeover .2899
Examine Sunlight Sensor 2900
How to Examine Sunlight Sensor .2900
Examine Refrigerant (Dual) Pressure Switch .2901
How to Examine Refrigerant (Dual) Pressure Switch 2901
Examine Relay 2902
How to Examine Relay .2902
Air Conditioner Troubleshooting Chart 1 2903
Air Conditioner Troubleshooting Chart 2 2904
Information Shown in Troubleshooting Table .2907
Failure Code [879AKA] 2908
Failure Code [879AKB] 2909
Failure Code [879BKA] 2910
Failure Code [879BKB] 2912
Failure Code [879CKA] 2914
Failure Code [879CKB] 2915
Failure Code [879DKZ] 2916
Failure Code [879EMC] 2918
Failure Code [879FMC] 2919
Failure Code [879GKX] 2920
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) .2922
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2924
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) .2927
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2929
Troubleshooting by Gauge Pressure 2931
Connect Service Tool .2934
How to Connect Service Tool 2934
Precautions for Disconnection and Connection of Air Conditioner Piping .2936
Handle Compressor Oil 2938
Replace Desiccant 2940
90 Circuit Diagrams 2943
Table of Contents 2944
Hydraulic Circuit Diagram 2945
Symbols Used in Hydraulic Circuit Diagram 2945
Hydraulic Circuit Diagram (1/2) 2949
Hydraulic Circuit Diagram (2/2) 2951
Electrical Circuit Diagram .2953
Symbols Used in Electric Circuit Diagram .2953
Electrical Circuit Diagram (1/9) .2957
Electrical Circuit Diagram (2/9) .2959
Electrical Circuit Diagram (3/9) .2961
Electrical Circuit Diagram (4/9) .2963
Electrical Circuit Diagram (5/9) .2965
Electrical Circuit Diagram (6/9) .2967
Electrical Circuit Diagram (7/9) .2969
Electrical Circuit Diagram (8/9) .2971
Electrical Circuit Diagram (9/9) .2973
INDEX .2975

DESCRIPTION:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06805-09  – PDF DOWNLOAD

• SERIAL NUMBERS 502361 and up

G.B 27/12/24