Komatsu PC210LCI -11E0 Hydraulic Excavator Shop Manual UENBM00570 PDF

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Komatsu PC210LCI -11E0 Hydraulic Excavator Shop Manual UENBM00570 – PDF DOWNLOAD

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Komatsu PC210LCI -11E0 Hydraulic Excavator Shop Manual UENBM00570 – PDF DOWNLOAD 

Language : English
Pages : 3962
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC210LCI -11E0 Hydraulic Excavator Shop Manual UENBM00570 – PDF DOWNLOAD 

SERIAL NUMBERS K77001 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 26
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
SPECIFICATIONS 97
SPECIFICATION DRAWING 97
SPECIFICATION DRAWING: PC210LCI-11E0 97
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC210LCI-11E0 99
SPECIFICATIONS 100
SPECIFICATIONS: PC210LCI-11E0 100
WEIGHT TABLE 103
WEIGHT TABLE: PC210LCI-11E0 103
TABLE OF FUEL, COOLANT, AND LUBRICANTS 105
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
UREA SCR SYSTEM 112
LAYOUT DRAWING OF UREA SCR SYSTEM 113
UREA SCR SYSTEM DIAGRAM 118
FUNCTION OF UREA SCR SYSTEM 119
FUNCTION OF AdBlue/DEF SYSTEM 119
INDUCEMENT STRATEGY 121
COMPONENT PARTS OF UREA SCR SYSTEM 129
AdBlue/DEF MIXING TUBE 129
SCR ASSEMBLY 129
AdBlue/DEF TANK 132
AdBlue/DEF PUMP 134
AdBlue/DEF INJECTOR 135
AdBlue/DEF HOSE 136
AdBlue/DEF TANK HEATING VALVE 137
BOOT-UP SYSTEM 138
LAYOUT DRAWING OF BOOT-UP SYSTEM 138
SYSTEM OPERATING LAMP SYSTEM 140
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 140
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 140
BATTERY DISCONNECT SWITCH 142
FUNCTION OF BATTERY DISCONNECT SWITCH 142
ENGINE SYSTEM 143
LAYOUT DRAWING OF ENGINE SYSTEM 143
SPECIFICATIONS OF ENGINE SYSTEM 144
FUNCTION OF ENGINE SYSTEM 144
ENGINE CONTROL SYSTEM 145
ENGINE CONTROL SYSTEM DIAGRAM 145
FUNCTION OF ENGINE CONTROL SYSTEM 146
AUTO-DECELERATION SYSTEM 148
AUTO-DECELERATION SYSTEM DIAGRAM 148
FUNCTION OF AUTO-DECELERATION SYSTEM 148
OPERATION OF AUTO-DECELERATION SYSTEM 149
ENGINE AUTOMATIC WARM-UP SYSTEM 150
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 150
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 151
OVERHEAT PREVENTION SYSTEM 152
OVERHEAT PREVENTION SYSTEM DIAGRAM 152
FUNCTION OF OVERHEAT PREVENTION SYSTEM 153
TURBOCHARGER PROTECTION SYSTEM 155
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 155
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 156
AUTOMATIC IDLE STOP SYSTEM 157
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 157
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 157
COMPONENT PARTS OF ENGINE SYSTEM 160
VGT 160
EGR SYSTEM 164
EGR VALVE 166
EGR COOLER 168
KCCV SYSTEM 169
KCCV VENTILATOR 171
KDPF 173
COOLING SYSTEM 178
LAYOUT DRAWING OF COOLING SYSTEM 178
SPECIFICATIONS OF COOLING SYSTEM 179
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 180
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 180
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 181
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 182
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 182
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 182
COMPONENT PARTS OF COOLING SYSTEM 184
FAN CLUTCH 184
CONTROL SYSTEM 185
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 185
MACHINE MONITOR SYSTEM 188
MACHINE MONITOR SYSTEM DIAGRAM 188
FUNCTION OF MACHINE MONITOR SYSTEM 188
KomVision SYSTEM 190
LAYOUT DRAWING OF KOMVISION SYSTEM 190
KomVision SYSTEM DIAGRAM 192
FUNCTION OF KomVision SYSTEM 192
KOMTRAX SYSTEM 194
KOMTRAX SYSTEM DIAGRAM 194
FUNCTION OF KOMTRAX SYSTEM 194
PPC LEVERS 195
LH PPC LEVER 195
RH PPC LEVER 196
AUTOMATIC GREASE SYSTEM 197
OUTLINE OF AUTO GREASE SYSTEM 197
COMPONENT PARTS OF CONTROL SYSTEM 212
MACHINE MONITOR 212
KomVision CONTROLLER 226
KomVision CAMERA 230
GATEWAY FUNCTION CONTROLLER 231
COMMUNICATION TERMINAL 234
PUMP CONTROLLER 236
RESISTOR FOR PC-EPC VALVE 240
CAN TERMINATING RESISTOR 240
PPC OIL PRESSURE SWITCH 241
ENGINE CONTROLLER 242
FUEL CONTROL DIAL 248
SENSOR 250
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 250
FUNCTION OF ENGINE OIL PRESSURE SWITCH 251
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 252
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 253
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 254
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 255
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 256
FUNCTION OF AUTO GREASE PRESSURE SWITCH 257
STRUCTURE OF OVERLOAD CAUTION SENSOR 258
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 259
FUNCTION OF OVERLOAD CAUTION SENSOR 260
HYDRAULIC SYSTEM 261
LAYOUT DRAWING OF HYDRAULIC SYSTEM 261
CLSS 267
STRUCTURE OF CLSS 267
OPERATION OF UNLOAD VALVE AND LS PRESSURE 269
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 270
PRESSURE COMPENSATION CONTROL 283
ENGINE AND PUMP COMBINED CONTROL SYSTEM 286
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 286
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 287
PUMP AND VALVE CONTROL SYSTEM 292
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 292
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 293
COMPONENT PARTS OF HYDRAULIC SYSTEM 295
HYDRAULIC TANK 295
MAIN PUMP 297
PILOT OIL FILTER 323
CONTROL VALVE 323
WORK EQUIPMENT SYSTEM 380
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 380
STRUCTURE OF VALVE CONTROL 385
BUCKET CONTROL SYSTEM 387
OPERATION OF BUCKET CONTROL SYSTEM 387
ONE-TOUCH POWER MAXIMIZING SYSTEM 388
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 388
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 389
PPC LOCK SYSTEM 390
PPC LOCK SYSTEM DIAGRAM 390
FUNCTION OF PPC LOCK SYSTEM 390
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 391
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 391
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 391
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 392
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 393
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 393
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 394
TOOL CONTROL SYSTEM 395
TOOL CONTROL SYSTEM DIAGRAM 395
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 397
WORK EQUIPMENT AND SWING PPC VALVE 397
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 402
2ND-LINE ATTACHMENT PPC VALVE 408
SOLENOID VALVE 410
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 413
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 415
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 418
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 420
ATTACHMENT BYPASS SOLENOID VALVE 423
ATT EPC VALVE ASSEMBLY 425
PILOT CIRCUIT ACCUMULATOR 426
ATTACHMENT CIRCUIT ACCUMULATOR 427
ICT SYSTEM 428
LAYOUT DRAWING OF ICT SYSTEM 428
ICT CONTROL SYSTEM DIAGRAM 432
BUCKET EDGE POSITION DETECTION SYSTEM 433
BUCKET EDGE POSITION DETECTION SYSTEM DIAGRAM 433
FUNCTION OF BUCKET EDGE POSITION DETECTION SYSTEM 433
OPERATION OF BUCKET EDGE POSITION DETECTION SYSTEM 433
THE INTELLIGENT MACHINE CONTROL SYSTEM 435
FUNCTION OF INTELLIGENT MACHINE CONTROL SYSTEM 435
AUTO GRADE ASSIST CONTROL 436
BUCKET ANGLE HOLD CONTROL 442
AUTO STOP CONTROL 444
TILT AUTOMATIC CONTROL (MACHINES WITH AUTO TILT BUCKET) 458
CUSHION SYSTEM FOR ARM IN END 461
CUSHION SYSTEM FOR ARM IN END DIAGRAM 461
FUNCTION OF CUSHION SYSTEM FOR ARM IN END 461
OPERATION OF CUSHION SYSTEM FOR ARM IN END 461
BOOM SECONDARY DRIVE SWITCH 463
CONTROL FUNCTION WHEN BOOM SECONDARY DRIVE SWITCH IS TURNED TO ON POSITION 463
COMPONENT PARTS OF ICT SYSTEM 464
ICT SENSOR CONTROLLER 464
WORK EQUIPMENT CONTROLLER 468
CONTROL BOX 472
GNSS RECEIVER 475
GNSS ANTENNA 477
IMU SENSOR 478
INTELLIGENT MACHINE CONTROL EPC VALVE 480
STROKE SENSOR FOR BOOM CYLINDER 483
STROKE SENSOR FOR ARM CYLINDER 484
STROKE AND RESET SENSOR FOR BUCKET CYLINDER 486
RESET SENSOR FOR BOOM CYLINDER 488
RESET SENSOR FOR ARM CYLINDER 489
BOOM SPOOL STROKE SENSOR 490
ARM SPOOL STROKE SENSOR 491
SWING SYSTEM 493
LAYOUT DRAWING OF SWING SYSTEM 493
SWING CONTROL SYSTEM DIAGRAM 497
FUNCTION OF SWING CONTROL SYSTEM 497
COMPONENT PARTS OF SWING SYSTEM 501
SWING MOTOR 501
SWING MACHINERY 512
SWING CIRCLE 513
TRAVEL SYSTEM 515
LAYOUT DRAWING OF TRAVEL SYSTEM 515
TRAVEL CONTROL SYSTEM DIAGRAM 519
FUNCTION OF TRAVEL CONTROL SYSTEM 519
COMPONENT PARTS OF TRAVEL SYSTEM 521
TRAVEL MOTOR 521
FINAL DRIVE 533
TRAVEL PPC VALVE 535
CENTER SWIVEL JOINT 540
UNDERCARRIAGE AND FRAME 542
LAYOUT DRAWING OF UNDERCARRIAGE 542
SPECIFICATIONS OF UNDERCARRIAGE 543
WORK EQUIPMENT 544
STRUCTURE OF WORK EQUIPMENT 544
FUNCTION OF WORK EQUIPMENT 545
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 546
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 546
BUCKET CLEARANCE ADJUSTMENT SHIM 547
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 547
CAB AND ITS ATTACHMENTS 548
ROPS CAB 548
STRUCTURE OF ROPS CAB 548
FUNCTION OF ROPS CAB 548
CAB MOUNT 549
STRUCTURE OF CAB MOUNT 549
FUNCTION OF CAB MOUNT 549
CAB TIPPING STOPPER 550
STRUCTURE OF CAB TIPPING STOPPER 550
FUNCTION OF CAB TIPPING STOPPER 550
20 STANDARD VALUE TABLE 551
CONTENTS 552
STANDARD VALUE TABLE FOR ENGINE 553
STANDARD VALUE TABLE FOR ENGINE:PC210LCI-11E0 553
STANDARD VALUE TABLE FOR MACHINE 557
STANDARD VALUE TABLE FOR MACHINE:PC210LCI-11E0 557
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 580
STANDARD VALUE TABLE FOR ELECTRICAL 584
30 TESTING AND ADJUSTING 595
CONTENTS 596
RELATED INFORMATION ON TESTING AND ADJUSTING 600
TOOLS FOR TESTING AND ADJUSTING 600
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 610
ENGINE AND COOLING SYSTEM 612
TEST ENGINE SPEED 612
METHOD FOR TESTING ENGINE SPEED 612
TEST BOOST PRESSURE 615
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 615
METHOD FOR TESTING BOOST PRESSURE 616
TEST EXHAUST GAS COLOR 617
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 617
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 618
TEST AND ADJUST VALVE CLEARANCE 620
METHOD FOR TESTING VALVE CLEARANCE 620
METHOD FOR ADJUSTING VALVE CLEARANCE 621
TEST COMPRESSION PRESSURE 623
METHOD FOR TESTING COMPRESSION PRESSURE 623
TEST BLOWBY PRESSURE 628
METHOD FOR TESTING BLOWBY PRESSURE 628
TEST ENGINE OIL PRESSURE 630
METHOD FOR TESTING ENGINE OIL PRESSURE 630
TEST EGR VALVE AND VGT OIL PRESSURE 631
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 631
TEST FUEL PRESSURE 633
METHOD FOR TESTING FUEL PRESSURE 634
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 639
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 640
BLEEDING AIR FROM FUEL SYSTEM 646
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 646
TEST FUEL CIRCUIT FOR LEAKAGE 647
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 647
HANDLE CYLINDER CUT-OUT MODE OPERATION 649
HANDLE NO-INJECTION CRANKING OPERATION 650
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 651
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 651
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 651
TEST COOLING FAN SPEED 653
METHOD FOR TESTING COOLING FAN SPEED 653
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 654
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 654
REPLACING FAN BELT 655
METHOD FOR REPLACING FAN BELT 655
TEST COOLING FAN SPEED 656
METHOD FOR TESTING COOLING FAN SPEED 656
TEST SCR RELATED FUNCTIONS 657
TEST AdBlue/DEF PUMP RAISED PRESSURE 660
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 663
TEST AdBlue/DEF LINE HEATER RELAY 1 667
TEST AdBlue/DEF LINE HEATER RELAY 2 670
TEST AdBlue/DEF PUMP HEATER RELAY 672
TEST AdBlue/DEF TANK HEATER VALVE 675
TEST DENITRATION EFFICIENCY OF SCR 678
CLEAN AdBlue/DEF TANK 682
METHOD FOR CLEANING AdBlue/DEF TANK 682
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 686
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 686
POWER TRAIN 688
TEST SWING CIRCLE BEARING CLEARANCE 688
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 688
UNDERCARRIAGE AND FRAME 689
TEST AND ADJUST TRACK TENSION 689
METHOD FOR TESTING TRACK TENSION 689
METHOD FOR ADJUSTING TRACK TENSION 689
HYDRAULIC SYSTEM 691
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 691
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 691
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 691
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 697
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 698
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 704
TEST OIL PRESSURE OF CONTROL CIRCUIT 707
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 707
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 709
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 709
TEST PC-EPC VALVE OUTLET PRESSURE 710
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 711
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 713
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 713
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 714
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 717
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 718
METHOD FOR ADJUSTING LS VALVE 719
TEST OUTLET PRESSURE OF SOLENOID VALVE 720
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 720
OPERATING CONDITION OF SOLENOID VALVE 721
TEST PPC VALVE OUTLET PRESSURE 724
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 724
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 726
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 726
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 727
TEST PUMP SWASH PLATE SENSOR 729
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 729
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 730
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 730
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 730
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 731
TEST OIL LEAKAGE 732
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 732
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 732
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 733
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 734
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 734
BLEED AIR FROM HYDRAULIC CIRCUIT 735
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 737
CAB AND ITS ATTACHMENTS 739
TEST CAB TIPPING STOPPER 739
METHOD FOR TESTING CAB TIPPING STOPPER 739
METHOD FOR ADJUSTING MIRRORS 740
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 740
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 741
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 742
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 743
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 744
ELECTRICAL SYSTEM 746
SET AND OPERATE MACHINE MONITOR 746
OPERATOR MODE 750
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 750
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 750
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 751
CHECKING FUNCTION OF SERVICE METER 752
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 752
SERVICE MODE 754
OPERATE SERVICE MODE 754
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 758
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 765
ABNORMALITY RECORD MENU 778
METHOD FOR CONFIRMING MAINTENANCE RECORD 783
METHOD FOR OPERATING MAINTENANCE MODE SETTING 784
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 788
DEFAULT MENU 789
DIAGNOSTIC TESTS MENU 797
ADJUSTMENT MENU 808
METHOD FOR PERFORMING NO-INJECTION CRANKING 846
KOMTRAX SETTINGS MENU 847
METHOD FOR DISPLAYING SERVICE MESSAGE 850
METHOD FOR STARTING UP KOMTRAX SYSTEM 852
ADJUST REARVIEW CAMERA ANGLE 857
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 857
ADJUST KomVision CAMERA ANGLE 860
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 861
ADJUST KomVision RELATED ITEMS 865
SETTING OF KomVision (MAIN SETTING) 865
SETTING OF KomVision (CAMERA SETTING) 867
SETTING OF KomVision (CAMERA CALIBRATION) 867
KomVision screen – Check 12 m visibility 881
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 884
HANDLE BATTERY DISCONNECT SWITCH 885
TEST DIODES 886
METHOD FOR TESTING DIODE USING DIGITAL TESTER 886
METHOD FOR TESTING DIODE USING ANALOG TESTER 886
ICT SYSTEM 887
SET AND OPERATE CONTROL BOX 887
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF THE CONTROL BOX 889
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX 892
SET GNSS RECEIVER TYPE 896
SET HEADING MODE 899
SWITCH GRADE TRANSITIONS FINENESS ON CONTROL BOX 903
MONITORING AND LOGGING FUNCTION ON CONTROL BOX 906
SET TILT AUTOMATIC CONTROL FUNCTION 911
CALIBRATE INTELLIGENT MACHINE CONTROL 915
PPC Pressure Sensor Calibration 917
Control Map Calibration 998
METHOD FOR TESTING THE INTELLIGENT MACHINE CONTROL SYSTEM 1166
CALIBRATE IMU SENSOR FOR YAW ANGLE 1172
IMU SENSOR CALIBRATION 1179
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF IMU SENSOR 1191
WORK EQUIPMENT CYLINDER CALIBRATION 1191
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF WORK EQUIPMENT CYLINDER 1204
GENERAL CALIBRATION OF BUCKET BLADE EDGE POSITION, BOOM DIMENSIONS, ARM DIMENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA POSITION WITH TOTAL STATION 1206
CALIBRATION OF BOOM DIMENSIONS AND ARM DIMENSIONS WITH TOTAL STATION 1258
CALIBRATION OF BUCKET LINK DIMENSIONS WITH TOTAL STATION 1278
CALIBRATION OF GNSS ANTENNA WITH TOTAL STATION 1315
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITH TOTAL STATION 1339
VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STATION 1341
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITH TOTAL STATION 1341
CALIBRATION OF GNSS ANTENNA WITHOUT TOTAL STATION 1342
CALIBRATION OF BUCKET BLADE EDGE POSITION WITHOUT TOTAL STATION 1347
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITHOUT TOTAL STATION 1357
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITHOUT TOTAL STATION 1357
Pm CLINIC 1359
Pm CLINIC SERVICE 1359
Pm CLINIC CHECK SHEET:PC210LCI-11E0 1363
40 TROUBLESHOOTING 1375
CONTENTS 1376
RELATED INFORMATION ON TROUBLESHOOTING 1390
GENERAL TROUBLESHOOTING POINTS 1390
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 1391
TABLE OF FAILURE CODES THAT IS SUBJECT TO INDUCEMENT 1398
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1402
CHECKS BEFORE TROUBLESHOOTING 1404
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1406
WALK-AROUND CHECK 1406
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1408
CHECK FUEL LEVEL AND TYPE 1408
CHECK IMPURE INGREDIENT IN FUEL 1408
CHECK FUEL PREFILTER 1409
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 1409
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 1410
CHECK MAIN FILTER 1411
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 1413
CHECK COOLANT LEVEL (RESERVOIR TANK) 1414
CHECK CLOGGING OF AIR CLEANER 1414
OUTER ELEMENT – CLEAN 1415
ELEMENTS – REPLACE 1417
CHECK HYDRAULIC OIL LEVEL 1418
CHECK HYDRAULIC OIL STRAINER 1419
CHECK HYDRAULIC FILTER 1420
CHECK OIL LEVEL IN SWING MACHINERY CASE 1421
CHECK OIL LEVEL IN DAMPER CASE 1422
CHECK OIL LEVEL IN FINAL DRIVE CASE 1422
BLEED AIR FROM FUEL SYSTEM 1423
BLEED AIR FROM HYDRAULIC SYSTEM 1423
ELECTRICAL EQUIPMENT – CHECK METHOD 1423
AUTOMATIC GREASE SYSTEM 1428
FINDING MALFUNCTIONS 1428
MALFUNCTION FINDING PROCEDURES 1430
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 1432
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1432
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 1432
PREPARATION FOR TROUBLESHOOTING OF ICT SENSOR CONTROLLER 1433
PREPARATION FOR TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER 1434
PREPARATION FOR TROUBLESHOOTING OF GATEWAY CONTROLLER 1435
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER 1438
PREPARATION FOR TROUBLESHOOTING OF CONTROL BOX 1439
PREPARATION FOR TROUBLESHOOTING OF GNSS RECIVER 1439
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 1439
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1443
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 1446
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1451
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1453
CONNECTOR LIST AND LAYOUT 1456
CONNECTOR CONTACT IDENTIFICATION 1479
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1519
FUSE LOCATION TABLE 1525
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1529
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1533
FAILURE CODES TABLE 1535
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1559
FAILURE CODE [879AKA] 1559
FAILURE CODE [879AKB] 1560
FAILURE CODE [879BKA] 1561
FAILURE CODE [879BKB] 1563
FAILURE CODE [879CKA] 1565
FAILURE CODE [879CKB] 1566
FAILURE CODE [879DKZ] 1567
FAILURE CODE [879EMC] 1569
FAILURE CODE [879FMC] 1570
FAILURE CODE [879GKX] 1571
FAILURE CODE [989L00] 1573
FAILURE CODE [989M00] 1574
FAILURE CODE [989N00] 1575
FAILURE CODE [A1U0N3] 1576
FAILURE CODE [A1U0N4] 1578
FAILURE CODE [A900FR] 1580
FAILURE CODE [A900N6] 1581
FAILURE CODE [A900NY] 1582
FAILURE CODE [AA10NX] 1583
FAILURE CODE [AB00KE] 1585
FAILURE CODE [AQ10N3] 1588
FAILURE CODE [AS00N3] 1589
FAILURE CODE [AS00R2] 1591
FAILURE CODE [AS00R3] 1592
FAILURE CODE [AS00R4] 1593
FAILURE CODE [AS00R5] 1594
FAILURE CODE [AS00R6] 1595
FAILURE CODE [AS00ZK] 1596
FAILURE CODE [AS10KM] 1597
FAILURE CODE [AS10NR] 1598
FAILURE CODE [AS10NT] 1599
FAILURE CODE [B@BAZG] 1600
FAILURE CODE [B@BAZK] 1601
FAILURE CODE [B@BCNS] 1603
FAILURE CODE [B@BCQA] 1604
FAILURE CODE [B@BCZK] 1606
FAILURE CODE [B@HANS] 1608
FAILURE CODE [CA115] 1609
FAILURE CODE [CA122] 1610
FAILURE CODE [CA123] 1612
FAILURE CODE [CA131] 1614
FAILURE CODE [CA132] 1616
FAILURE CODE [CA144] 1618
FAILURE CODE [CA145] 1620
FAILURE CODE [CA153] 1622
FAILURE CODE [CA154] 1625
FAILURE CODE [CA187] 1627
FAILURE CODE [CA221] 1629
FAILURE CODE [CA222] 1631
FAILURE CODE [CA227] 1633
FAILURE CODE [CA234] 1634
FAILURE CODE [CA238] 1635
FAILURE CODE [CA239] 1637
FAILURE CODE [CA249] 1639
FAILURE CODE [CA256] 1641
FAILURE CODE [CA271] 1643
FAILURE CODE [CA272] 1645
FAILURE CODE [CA322] 1647
FAILURE CODE [CA323] 1649
FAILURE CODE [CA324] 1651
FAILURE CODE [CA325] 1653
FAILURE CODE [CA331] 1655
FAILURE CODE [CA332] 1657
FAILURE CODE [CA343] 1659
FAILURE CODE [CA351] 1660
FAILURE CODE [CA352] 1661
FAILURE CODE [CA356] 1664
FAILURE CODE [CA357] 1666
FAILURE CODE [CA386] 1668
FAILURE CODE [CA428] 1669
FAILURE CODE [CA429] 1671
FAILURE CODE [CA435] 1673
FAILURE CODE [CA441] 1675
FAILURE CODE [CA442] 1677
FAILURE CODE [CA449] 1678
FAILURE CODE [CA451] 1679
FAILURE CODE [CA452] 1681
FAILURE CODE [CA488] 1683
FAILURE CODE [CA515] 1684
FAILURE CODE [CA516] 1686
FAILURE CODE [CA553] 1688
FAILURE CODE [CA555] 1689
FAILURE CODE [CA556] 1690
FAILURE CODE [CA559] 1691
FAILURE CODE [CA595] 1694
FAILURE CODE [CA687] 1695
FAILURE CODE [CA689] 1697
FAILURE CODE [CA691] 1700
FAILURE CODE [CA692] 1702
FAILURE CODE [CA697] 1704
FAILURE CODE [CA698] 1705
FAILURE CODE [CA731] 1706
FAILURE CODE [CA778] 1708
FAILURE CODE [CA1117] 1713
FAILURE CODE [CA1664] 1714
FAILURE CODE [CA1669] 1716
FAILURE CODE [CA1673] 1717
FAILURE CODE [CA1677] 1718
FAILURE CODE [CA1678] 1719
FAILURE CODE [CA1682] 1720
FAILURE CODE [CA1683] 1722
FAILURE CODE [CA1684] 1724
FAILURE CODE [CA1686] 1726
FAILURE CODE [CA1691] 1727
FAILURE CODE [CA1694] 1730
FAILURE CODE [CA1695] 1733
FAILURE CODE [CA1696] 1734
FAILURE CODE [CA1712] 1736
FAILURE CODE [CA1713] 1739
FAILURE CODE [CA1714] 1741
FAILURE CODE [CA1715] 1742
FAILURE CODE [CA1776] 1743
FAILURE CODE [CA1777] 1746
FAILURE CODE [CA1843] 1749
FAILURE CODE [CA1844] 1751
FAILURE CODE [CA1879] 1754
FAILURE CODE [CA1881] 1756
FAILURE CODE [CA1883] 1758
FAILURE CODE [CA1885] 1761
FAILURE CODE [CA1887] 1763
FAILURE CODE [CA1921] 1765
FAILURE CODE [CA1922] 1768
FAILURE CODE [CA1942] 1773
FAILURE CODE [CA1993] 1774
FAILURE CODE [CA2185] 1777
FAILURE CODE [CA2186] 1778
FAILURE CODE [CA2249] 1780
FAILURE CODE [CA2271] 1781
FAILURE CODE [CA2272] 1784
FAILURE CODE [CA2288] 1787
FAILURE CODE [CA2311] 1788
FAILURE CODE [CA2349] 1789
FAILURE CODE [CA2353] 1792
FAILURE CODE [CA2357] 1794
FAILURE CODE [CA2381] 1795
FAILURE CODE [CA2382] 1798
FAILURE CODE [CA2383] 1801
FAILURE CODE [CA2386] 1804
FAILURE CODE [CA2387] 1806
FAILURE CODE [CA2555] 1807
FAILURE CODE [CA2556] 1810
FAILURE CODE [CA2637] 1813
FAILURE CODE [CA2639] 1815
FAILURE CODE [CA2771] 1818
FAILURE CODE [CA2777] 1824
FAILURE CODE [CA2976] 1827
FAILURE CODE [CA3133] 1829
FAILURE CODE [CA3134] 1832
FAILURE CODE [CA3135] 1834
FAILURE CODE [CA3142] 1837
FAILURE CODE [CA3143] 1838
FAILURE CODE [CA3144] 1839
FAILURE CODE [CA3146] 1841
FAILURE CODE [CA3147] 1842
FAILURE CODE [CA3148] 1843
FAILURE CODE [CA3151] 1845
FAILURE CODE [CA3165] 1851
FAILURE CODE [CA3229] 1853
FAILURE CODE [CA3231] 1855
FAILURE CODE [CA3232] 1857
FAILURE CODE [CA3235] 1861
FAILURE CODE [CA3239] 1863
FAILURE CODE [CA3241] 1866
FAILURE CODE [CA3242] 1869
FAILURE CODE [CA3251] 1872
FAILURE CODE [CA3253] 1874
FAILURE CODE [CA3254] 1877
FAILURE CODE [CA3255] 1880
FAILURE CODE [CA3256] 1884
FAILURE CODE [CA3311] 1886
FAILURE CODE [CA3312] 1888
FAILURE CODE [CA3313] 1891
FAILURE CODE [CA3314] 1892
FAILURE CODE [CA3315] 1893
FAILURE CODE [CA3316] 1895
FAILURE CODE [CA3317] 1896
FAILURE CODE [CA3318] 1897
FAILURE CODE [CA3319] 1899
FAILURE CODE [CA3321] 1900
FAILURE CODE [CA3322] 1902
FAILURE CODE [CA3419] 1904
FAILURE CODE [CA3421] 1906
FAILURE CODE [CA3497] 1908
FAILURE CODE [CA3498] 1909
FAILURE CODE [CA3543] 1910
FAILURE CODE [CA3545] 1917
FAILURE CODE [CA3547] 1919
FAILURE CODE [CA3558] 1920
FAILURE CODE [CA3559] 1922
FAILURE CODE [CA3562] 1924
FAILURE CODE [CA3563] 1926
FAILURE CODE [CA3567] 1929
FAILURE CODE [CA3568] 1932
FAILURE CODE [CA3571] 1936
FAILURE CODE [CA3572] 1938
FAILURE CODE [CA3574] 1940
FAILURE CODE [CA3575] 1942
FAILURE CODE [CA3577] 1944
FAILURE CODE [CA3578] 1946
FAILURE CODE [CA3582] 1948
FAILURE CODE [CA3583] 1954
FAILURE CODE [CA3596] 1956
FAILURE CODE [CA3649] 1958
FAILURE CODE [CA3681] 1960
FAILURE CODE [CA3682] 1965
FAILURE CODE [CA3713] 1971
FAILURE CODE [CA3717] 1974
FAILURE CODE [CA3718] 1975
FAILURE CODE [CA3725] 1976
FAILURE CODE [CA3741] 1979
FAILURE CODE [CA3748] 1980
FAILURE CODE [CA3751] 1982
FAILURE CODE [CA3755] 1984
FAILURE CODE [CA3866] 1986
FAILURE CODE [CA3867] 1990
FAILURE CODE [CA3868] 1993
FAILURE CODE [CA3899] 1997
FAILURE CODE [CA3911] 1999
FAILURE CODE [CA3912] 2003
FAILURE CODE [CA3932] 2005
FAILURE CODE [CA3933] 2007
FAILURE CODE [CA3934] 2009
FAILURE CODE [CA3935] 2012
FAILURE CODE [CA3936] 2014
FAILURE CODE [CA4151] 2016
FAILURE CODE [CA4152] 2020
FAILURE CODE [CA4155] 2024
FAILURE CODE [CA4156] 2026
FAILURE CODE [CA4157] 2029
FAILURE CODE [CA4158] 2031
FAILURE CODE [CA4159] 2032
FAILURE CODE [CA4161] 2033
FAILURE CODE [CA4162] 2036
FAILURE CODE [CA4163] 2039
FAILURE CODE [CA4164] 2040
FAILURE CODE [CA4165] 2042
FAILURE CODE [CA4166] 2044
FAILURE CODE [CA4168] 2045
FAILURE CODE [CA4169] 2048
FAILURE CODE [CA4171] 2050
FAILURE CODE [CA4249] 2053
FAILURE CODE [CA4251] 2055
FAILURE CODE [CA4259] 2057
FAILURE CODE [CA4261] 2060
FAILURE CODE [CA4277] 2063
FAILURE CODE [CA4281] 2067
FAILURE CODE [CA4459] 2070
FAILURE CODE [CA4461] 2073
FAILURE CODE [CA4658] 2076
FAILURE CODE [CA4731] 2080
FAILURE CODE [CA4732] 2081
FAILURE CODE [CA4739] 2082
FAILURE CODE [CA4768] 2083
FAILURE CODE [CA4769] 2085
FAILURE CODE [CA4842] 2088
FAILURE CODE [CA4952] 2092
FAILURE CODE [CA5115] 2094
FAILURE CODE [CA5179] 2097
FAILURE CODE [CA5181] 2099
FAILURE CODE [CA5383] 2101
FAILURE CODE [D110KB] 2103
FAILURE CODE [D19JKZ] 2105
FAILURE CODE [D1M3KA] 2108
FAILURE CODE [D1M3KB] 2110
FAILURE CODE [D1M3KY] 2112
FAILURE CODE [D1M3MA] 2114
FAILURE CODE [D1M4KA] 2115
FAILURE CODE [D1M4KB] 2117
FAILURE CODE [D1M4KY] 2119
FAILURE CODE [D1M5KA] 2120
FAILURE CODE [D1M5KB] 2122
FAILURE CODE [D1M5KY] 2124
FAILURE CODE [D1M5MA] 2126
FAILURE CODE [D811MC] 2127
FAILURE CODE [D862KA] 2128
FAILURE CODE [D8ALKA] 2130
FAILURE CODE [D8ALKB] 2133
FAILURE CODE [D8AQKR] 2136
FAILURE CODE [D8G1KT] 2144
FAILURE CODE [D8G6KT] 2145
FAILURE CODE [DA20MC] 2146
FAILURE CODE [DA22KK] 2147
FAILURE CODE [DA25KP] 2150
FAILURE CODE [DA26KP] 2153
FAILURE CODE [DA29KQ] 2155
FAILURE CODE [DA2LKA] 2158
FAILURE CODE [DA2LKB] 2162
FAILURE CODE [DA2QKR] 2165
FAILURE CODE [DA2RKR] 2175
FAILURE CODE [DAF0KM] 2177
FAILURE CODE [DAF0MB] 2178
FAILURE CODE [DAF0MC] 2179
FAILURE CODE [DAF8KB] 2180
FAILURE CODE [DAF9KQ] 2182
FAILURE CODE [DAFGMC] 2183
FAILURE CODE [DAFLKA] 2184
FAILURE CODE [DAFLKB] 2188
FAILURE CODE [DAFQKR] 2191
FAILURE CODE [DAZ9KQ] 2200
FAILURE CODE [DAZQKR] 2201
FAILURE CODE [DB2QKR] 2206
FAILURE CODE [DB2RKR] 2215
FAILURE CODE [DB90MC] 2220
FAILURE CODE [DB92KK] 2221
FAILURE CODE [DB95KP] 2223
FAILURE CODE [DB96KP] 2227
FAILURE CODE [DB99KQ] 2231
FAILURE CODE [DB9LKA] 2234
FAILURE CODE [DB9LKB] 2238
FAILURE CODE [DB9QKR] 2241
FAILURE CODE [DB9RKR] 2251
FAILURE CODE [DBP0KM] 2257
FAILURE CODE [DBP0KT] 2258
FAILURE CODE [DBP5KB] 2259
FAILURE CODE [DBP5KY] 2262
FAILURE CODE [DBPQKR] 2265
FAILURE CODE [DBR0MC] 2274
FAILURE CODE [DBR2KK] 2275
FAILURE CODE [DBR5KP] 2278
FAILURE CODE [DBR6KP] 2280
FAILURE CODE [DBR9KQ] 2282
FAILURE CODE [DBRLKA] 2285
FAILURE CODE [DBRLKB] 2289
FAILURE CODE [DBRQKR] 2292
FAILURE CODE [DBRRKR] 2301
FAILURE CODE [DBRSKB] 2307
FAILURE CODE [DBRTKB] 2309
FAILURE CODE [DBUSKR] 2311
FAILURE CODE [DD20MA] 2315
FAILURE CODE [DDNRKA] 2318
FAILURE CODE [DDNRKY] 2320
FAILURE CODE [DDNS00] 2322
FAILURE CODE [DFB1KZ] 2324
FAILURE CODE [DFB2KZ] 2326
FAILURE CODE [DFB3L8] 2328
FAILURE CODE [DFB4L8] 2330
FAILURE CODE [DFB5KZ] 2332
FAILURE CODE [DFB6KZ] 2334
FAILURE CODE [DGH2KA] 2336
FAILURE CODE [DGH2KB] 2338
FAILURE CODE [DHA4KA] 2340
FAILURE CODE [DHAAMA] 2342
FAILURE CODE [DHACMA] 2344
FAILURE CODE [DHPAMA] 2346
FAILURE CODE [DHPBMA] 2348
FAILURE CODE [DHS3MA] 2350
FAILURE CODE [DHS4MA] 2353
FAILURE CODE [DHS8MA] 2356
FAILURE CODE [DHS9MA] 2359
FAILURE CODE [DHSAMA] 2362
FAILURE CODE [DHSBMA] 2365
FAILURE CODE [DHSCMA] 2368
FAILURE CODE [DHSDMA] 2371
FAILURE CODE [DHSFMA] 2374
FAILURE CODE [DHSGMA] 2377
FAILURE CODE [DHSHMA] 2380
FAILURE CODE [DHSJMA] 2383
FAILURE CODE [DHUXMA] 2386
FAILURE CODE [DHUYMA] 2388
FAILURE CODE [DHX1MA] 2390
FAILURE CODE [DHZAMA] 2393
FAILURE CODE [DHZCL8] 2397
FAILURE CODE [DK80KM] 2398
FAILURE CODE [DK80KR] 2399
FAILURE CODE [DK80KT] 2404
FAILURE CODE [DK8DKB] 2405
FAILURE CODE [DK8CKT] 2407
FAILURE CODE [DK8CKR] 2408
FAILURE CODE [DKG1KM] 2412
FAILURE CODE [DKG1L8] 2413
FAILURE CODE [DKR0MA] 2414
FAILURE CODE [DKR1MA] 2416
FAILURE CODE [DKT0KM] 2418
FAILURE CODE [DKT0L8] 2419
FAILURE CODE [DKT1KA] 2420
FAILURE CODE [DKT1KB] 2422
FAILURE CODE [DKT2KA] 2424
FAILURE CODE [DKT2KB] 2426
FAILURE CODE [DKT4KM] 2428
FAILURE CODE [DKT4L8] 2429
FAILURE CODE [DKT5KA] 2430
FAILURE CODE [DKT5KB] 2432
FAILURE CODE [DKT6KA] 2434
FAILURE CODE [DKT6KB] 2436
FAILURE CODE [DKT8KA] 2438
FAILURE CODE [DKT8KB] 2440
FAILURE CODE [DKT9KA] 2442
FAILURE CODE [DKT9KB] 2444
FAILURE CODE [DKTAKA] 2446
FAILURE CODE [DKTAKB] 2448
FAILURE CODE [DKTAMB] 2450
FAILURE CODE [DKTBKX] 2451
FAILURE CODE [DKTBMC] 2453
FAILURE CODE [DKTEMB] 2454
FAILURE CODE [DKTFKX] 2456
FAILURE CODE [DKTFMC] 2458
FAILURE CODE [DKTJMB] 2459
FAILURE CODE [DKTUL8] 2461
FAILURE CODE [DKTVKA] 2462
FAILURE CODE [DKTVKB] 2464
FAILURE CODE [DKTWKA] 2465
FAILURE CODE [DKTWKB] 2467
FAILURE CODE [DKU1MA] 2468
FAILURE CODE [DKU2MA] 2469
FAILURE CODE [DKUGKA] 2470
FAILURE CODE [DKUGKB] 2472
FAILURE CODE [DKUGKY] 2474
FAILURE CODE [DKUHKA] 2476
FAILURE CODE [DKUHKB] 2478
FAILURE CODE [DKUHKY] 2480
FAILURE CODE [DKULKA] 2482
FAILURE CODE [DKULKB] 2484
FAILURE CODE [DKULKY] 2486
FAILURE CODE [DKV0KA] 2488
FAILURE CODE [DKV0KY] 2491
FAILURE CODE [DKV1KA] 2493
FAILURE CODE [DKV1KY] 2495
FAILURE CODE [DKV2KA] 2497
FAILURE CODE [DKV2KY] 2499
FAILURE CODE [DKV3KA] 2501
FAILURE CODE [DKV3KY] 2503
FAILURE CODE [DKV4MA] 2505
FAILURE CODE [DKV5MA] 2508
FAILURE CODE [DKV6MA] 2511
FAILURE CODE [DKV7MA] 2514
FAILURE CODE [DKV8MA] 2517
FAILURE CODE [DKV9MA] 2520
FAILURE CODE [DKVAMA] 2523
FAILURE CODE [DKVBKA] 2526
FAILURE CODE [DKVBKB] 2528
FAILURE CODE [DKVBKY] 2530
FAILURE CODE [DKVCKA] 2532
FAILURE CODE [DKVCKB] 2534
FAILURE CODE [DKVCKY] 2536
FAILURE CODE [DKVDKA] 2538
FAILURE CODE [DKVDKB] 2540
FAILURE CODE [DKVDKY] 2542
FAILURE CODE [DKVDMA] 2544
FAILURE CODE [DKVLMA] 2546
FAILURE CODE [DKVMMA] 2549
FAILURE CODE [DKVNKX] 2552
FAILURE CODE [DKVNL8] 2553
FAILURE CODE [DKVKKX] 2554
FAILURE CODE [DKVKL8] 2555
FAILURE CODE [DKVPMA] 2556
FAILURE CODE [DKVQMA] 2559
FAILURE CODE [DLM5KA] 2562
FAILURE CODE [DLM5MB] 2564
FAILURE CODE [DR10KA] 2566
FAILURE CODE [DR12KA] 2569
FAILURE CODE [DR20KA] 2571
FAILURE CODE [DR21KX] 2573
FAILURE CODE [DR30KA] 2575
FAILURE CODE [DR31KX] 2577
FAILURE CODE [DR40KA] 2579
FAILURE CODE [DUMBKA] 2581
FAILURE CODE [DUMBKB] 2585
FAILURE CODE [DV20KB] 2588
FAILURE CODE [DW43KA] 2590
FAILURE CODE [DW43KB] 2592
FAILURE CODE [DW43KY] 2594
FAILURE CODE [DW45KA] 2596
FAILURE CODE [DW45KB] 2599
FAILURE CODE [DW45KY] 2602
FAILURE CODE [DW4CKY] 2604
FAILURE CODE [DW4FKA] 2606
FAILURE CODE [DW4FKB] 2609
FAILURE CODE [DW4FKY] 2611
FAILURE CODE [DW4GKA] 2613
FAILURE CODE [DW4GKB] 2616
FAILURE CODE [DW4GKY] 2618
FAILURE CODE [DW4SKA] 2620
FAILURE CODE [DW4SKB] 2622
FAILURE CODE [DW4SKY] 2624
FAILURE CODE [DW91KA] 2626
FAILURE CODE [DW91KB] 2628
FAILURE CODE [DW91KY] 2630
FAILURE CODE [DWA2KA] 2632
FAILURE CODE [DWA2KB] 2634
FAILURE CODE [DWA2KY] 2636
FAILURE CODE [DWK0KA] 2638
FAILURE CODE [DWK0KB] 2640
FAILURE CODE [DWK0KY] 2642
FAILURE CODE [DWK2KA] 2644
FAILURE CODE [DWK2KB] 2646
FAILURE CODE [DWK2KY] 2648
FAILURE CODE [DWK8KA] 2650
FAILURE CODE [DWK8KB] 2652
FAILURE CODE [DWK8KY] 2654
FAILURE CODE [DWN5KA] 2656
FAILURE CODE [DWN5KB] 2658
FAILURE CODE [DWN5KY] 2660
FAILURE CODE [DWPUKA] 2662
FAILURE CODE [DWPUKB] 2664
FAILURE CODE [DWPUKY] 2666
FAILURE CODE [DXA8KA] 2667
FAILURE CODE [DXA8KB] 2669
FAILURE CODE [DXA9KA] 2671
FAILURE CODE [DXA9KB] 2673
FAILURE CODE [DXE0KA] 2675
FAILURE CODE [DXE0KB] 2676
FAILURE CODE [DXE4KA] 2678
FAILURE CODE [DXE4KB] 2680
FAILURE CODE [DXE4KY] 2682
FAILURE CODE [DXE5KA] 2684
FAILURE CODE [DXE5KB] 2686
FAILURE CODE [DXE6KA] 2688
FAILURE CODE [DXE6KB] 2690
FAILURE CODE [DXE7KA] 2692
FAILURE CODE [DXE7KB] 2694
FAILURE CODE [DXE7KY] 2696
FAILURE CODE [DXE8KA] 2698
FAILURE CODE [DXE8KB] 2700
FAILURE CODE [DXE8KY] 2702
FAILURE CODE [DXE9KA] 2704
FAILURE CODE [DXE9KB] 2706
FAILURE CODE [DXE9KY] 2708
FAILURE CODE [DXEAKA] 2710
FAILURE CODE [DXEAKB] 2712
FAILURE CODE [DXEAKY] 2714
FAILURE CODE [DXEKKA] 2716
FAILURE CODE [DXEKKB] 2718
FAILURE CODE [DXEKKY] 2720
FAILURE CODE [DXELKA] 2721
FAILURE CODE [DXELKB] 2723
FAILURE CODE [DXELKY] 2725
FAILURE CODE [DXRWKA] 2726
FAILURE CODE [DXRWKB] 2728
FAILURE CODE [DXRWKY] 2730
FAILURE CODE [DXRXKA] 2732
FAILURE CODE [DXRXKB] 2734
FAILURE CODE [DXRXKY] 2736
FAILURE CODE [DXRYKA] 2738
FAILURE CODE [DXRYKB] 2740
FAILURE CODE [DXRYKY] 2742
FAILURE CODE [DY20KA] 2744
FAILURE CODE [DY20MA] 2746
FAILURE CODE [DY2CKB] 2748
FAILURE CODE [DY2DKB] 2751
FAILURE CODE [DY2EKB] 2753
FAILURE CODE [F313KA] 2755
FAILURE CODE [F313KB] 2757
FAILURE CODE [F318KB] 2760
FAILURE CODE [F318KY] 2763
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2765
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2765
MANUAL PREHEATING SYSTEM DOES NOT WORK 2771
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2774
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2776
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2778
WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2781
WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2782
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2783
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2784
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2785
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2786
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2787
WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2788
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2789
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2790
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2791
FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2792
DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2794
ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2795
DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2796
HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2797
DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2799
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2800
FUNCTION SWITCH DOES NOT OPERATE 2801
AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2802
WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2803
AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2804
WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2805
WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2806
WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2807
WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2808
ALARM BUZZER CANNOT BE CANCELED 2810
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2811
SERVICE MODE CANNOT BE SELECTED 2812
ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2813
ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2816
BUCKET DOES NOT MOVE WITH AUTO TILT FUNCTION 2818
WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2819
WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2822
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2824
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2827
ALARM DOES NOT SOUND DURING TRAVEL 2828
ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2830
HORN DOES NOT SOUND 2831
HORN DOES NOT STOP SOUNDING 2834
WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2836
WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2837
WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2839
BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2840
BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2841
ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2842
ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2843
BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2844
BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2845
SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2846
TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2847
SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2848
ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2850
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2851
CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected!] AND [Slope sensor not connected!] 2852
CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!] 2855
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link ] 2858
CONTROL BOX DISPLAYS THE MESSAGE [Tilt Bucket Sensor Offline!] 2859
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites ] 2860
CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] 2861
CONTROL BOX DISPLAYS THE MESSAGE [Sensors are invalid] 2864
CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize ] 2867
CONTROL BOX DISPLAYS THE MESSAGE [Initializing ] 2868
CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization ] 2869
CONTROL BOX DISPLAYS THE MESSAGE [Low precisions ] 2870
CONTROL BOX DISPLAYS [Out of design area ] 2871
CONTROL BOX DISPLAYS THE MESSAGE [Avoidance Area Breach!] 2872
CONTROL BOX SHOWS THE MESSAGE [CPU LOAD IS INCREASED] 2873
CONTROL BOX CAN NOT BE TURNED ON 2874
CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN 2875
CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE 2876
CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE 2877
CONTROL BOX TOUCH PANEL DOES NOT RESPOND 2878
CONTROL BOX TOUCH PANEL IS INACCURATE 2879
WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE 2880
SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED 2882
AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED 2883
AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED 2884
“SEMI-AUTOMATIC MODE” IS SHOWN BUT THE WORK MODE ICON IS NOT SHOWN 2885
BUCKET ANGLE HOLD CONTROL DOES NOT OPERATE 2886
BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE ASSIST FUNCTION IS ON 2887
BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO STOP CONTROL FUNCTION IS ON 2889
FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET 2891
NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS 2892
CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK 2893
CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK 2894
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2897
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2897
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2898
FAILURE MODE AND CAUSE TABLE 2900
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2909
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2910
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2913
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2914
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2915
H-6 SPEED OR POWER OF BOOM IS LOW 2917
H-7 ARM SPEED OR POWER IS LOW 2921
H-8 BUCKET SPEED OR POWER IS LOW 2926
H-9 BUCKET DOES NOT MOVE IN SINGLE OPERATION WITH AUTO TILT FUNCTION 2929
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2930
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE 2931
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 2933
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE 2935
H-14 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2936
H-15 TIME LAG OF WORK EQUIPMENT IS LARGE 2937
H-16 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2938
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2939
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2940
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2941
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2942
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2943
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2944
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2946
H-24 TRAVEL SPEED IS LOW 2949
H-25 ONE OF TRACKS DOES NOT RUN 2951
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2952
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2953
H-28 SWINGS ONLY IN ONE DIRECTION 2954
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2955
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2956
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2957
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2958
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2959
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2960
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2961
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2962
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2963
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2964
H-38 Quick coupler cylinder will not extend 2965
H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) 2967
H-40 Buzzer does not sound (but quick coupler cylinder doesretract) 2969
H-41 Quick coupler cylinder extends and retracts slowly 2971
TROUBLESHOOTING OF ENGINE (S-MODE) 2972
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2972
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2973
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2974
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2975
S-4 ENGINE STARTABILITY IS POOR 2977
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2979
S-6 ENGINE STOPS DURING OPERATION 2981
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2983
S-8 ENGINE LACKS POWER 2984
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2986
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2988
S-11 OIL BECOMES CONTAMINATED QUICKLY 2989
S-12 FUEL CONSUMPTION IS EXCESSIVE 2990
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2991
S-14 OIL PRESSURE DROPS 2992
S-15 FUEL MIXES INTO ENGINE OIL 2994
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2995
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2996
S-18 UNUSUAL NOISE IS HEARD 2997
S-19 VIBRATION IS EXCESSIVE 2998
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2999
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 3000
S-22 ACTIVE REGENERATION TAKES TIME 3002
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 3003
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 3004
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 3006
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 3007
50 DISASSEMBLY AND ASSEMBLY 3009
CONTENTS 3010
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 3016
HOW TO READ THIS MANUAL 3016
COATING MATERIALS LIST 3018
SPECIAL TOOLS LIST 3022
SKETCHES OF SPECIAL TOOLS 3034
ENGINE AND COOLING SYSTEM 3040
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 3040
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 3040
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 3043
REMOVE AND INSTALL INJECTOR ASSEMBLY 3046
METHOD FOR REMOVING INJECTOR ASSEMBLY 3046
METHOD FOR INSTALLING INJECTOR ASSEMBLY 3051
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 3059
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 3060
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 3069
REMOVE AND INSTALL EGR VALVE ASSEMBLY 3085
METHOD FOR REMOVING EGR VALVE ASSEMBLY 3085
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 3086
REMOVE AND INSTALL EGR COOLER ASSEMBLY 3088
METHOD FOR REMOVING EGR COOLER ASSEMBLY 3088
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 3092
REMOVE AND INSTALL STARTER ASSEMBLY 3097
METHOD FOR REMOVING STARTER ASSEMBLY 3097
METHOD FOR INSTALLING STARTER ASSEMBLY 3098
REMOVE AND INSTALL ALTERNATOR BELT 3101
METHOD FOR REMOVING ALTERNATOR BELT 3101
METHOD FOR INSTALLING ALTERNATOR BELT 3103
REMOVE AND INSTALL RADIATOR ASSEMBLY 3106
METHOD FOR REMOVING RADIATOR ASSEMBLY 3106
METHOD FOR INSTALLING RADIATOR ASSEMBLY 3108
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 3111
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 3111
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 3114
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 3117
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 3117
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 3119
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 3121
REMOVE FAN CLUTCH ASSEMBLY 3121
INSTALL FAN CLUTCH ASSEMBLY 3126
REMOVE AND INSTALL FAN 3130
METHOD FOR INSTALLING FAN 3130
METHOD FOR REMOVING FAN 3130
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 3131
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 3131
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 3140
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 3152
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 3152
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 3155
REMOVE AND INSTALL ENGINE REAR OIL SEAL 3159
METHOD FOR REMOVING ENGINE REAR OIL SEAL 3159
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 3160
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 3163
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 3163
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 3163
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 3165
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 3165
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 3167
REMOVE AND INSTALL FUEL TANK ASSEMBLY 3172
METHOD FOR REMOVING FUEL TANK ASSEMBLY 3172
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 3176
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 3182
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 3182
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 3188
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3194
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3194
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3200
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 3206
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 3206
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 3206
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 3208
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 3208
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 3208
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 3209
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 3209
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 3211
REMOVE AND INSTALL KDPF ASSEMBLY 3214
METHOD FOR REMOVING KDPF ASSEMBLY 3214
METHOD FOR INSTALLING KDPF ASSEMBLY 3216
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 3218
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 3219
METHOD FOR ASSEMBLING KDPF ASSEMBLY 3222
REMOVE AND INSTALL SCR ASSEMBLY 3227
METHOD FOR REMOVING SCR ASSEMBLY 3227
METHOD FOR INSTALLING SCR ASSEMBLY 3229
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 3231
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 3231
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 3237
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 3243
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 3243
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 3251
REMOVE AND INSTALL KCCV ASSEMBLY 3259
METHOD FOR REMOVING KCCV ASSEMBLY 3259
METHOD FOR INSTALLING KCCV ASSEMBLY 3261
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3266
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3266
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3272
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3278
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3278
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3281
REMOVE AND INSTALL AdBlue/DEF PUMP 3284
METHOD FOR REMOVING AdBlue/DEF PUMP 3284
METHOD FOR INSTALLING AdBlue/DEF PUMP 3287
REMOVE AND INSTALL AdBlue/DEF HOSE 3290
METHOD FOR REMOVING AdBlue/DEF HOSE 3290
METHOD FOR INSTALLING AdBlue/DEF HOSE 3298
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3304
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3304
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3305
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3307
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3307
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3309
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3312
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3312
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3313
POWER TRAIN 3314
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 3314
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 3314
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 3315
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 3317
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 3317
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 3321
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 3330
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 3330
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 3332
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 3336
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 3336
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 3340
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 3347
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 3347
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 3348
UNDERCARRIAGE AND FRAME 3349
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 3349
METHOD FOR SEPARATING TRACK ASSEMBLY 3349
METHOD FOR INSTALLING TRACK ASSEMBLY 3351
REMOVE AND INSTALL SPROCKET 3354
METHOD FOR REMOVING SPROCKET 3354
METHOD FOR INSTALLING SPROCKET 3354
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 3356
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 3356
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 3357
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 3358
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 3358
METHOD FOR ASSEMBLING IDLER ASSEMBLY 3359
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 3363
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 3364
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 3364
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 3366
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 3367
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 3368
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 3370
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 3370
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 3372
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 3374
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 3374
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 3376
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3379
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3379
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3382
HYDRAULIC SYSTEM 3386
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 3386
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 3386
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 3388
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 3391
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 3391
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 3392
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3394
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3394
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3397
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 3400
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 3400
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 3403
REMOVE AND INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL 3406
REMOVE JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL 3406
INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL 3410
REMOVE AND INSTALL PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL 3415
METHOD FOR REMOVING PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL 3415
METHOD FOR INSTALLING PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL 3417
REMOVE AND INSTALL BOOM SPOOL STROKE SENSOR 3419
METHOD FOR REMOVING BOOM SPOOL STROKE SENSOR 3419
METHOD FOR INSTALLING BOOM SPOOL STROKE SENSOR 3419
REMOVE AND INSTALL ARM SPOOL STROKE SENSOR 3421
METHOD FOR REMOVING ARM SPOOL STROKE SENSOR 3421
METHOD FOR INSTALLING ARM SPOOL STROKE SENSOR 3421
REMOVE AND INSTALL JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL 3423
METHOD FOR REMOVING JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL 3423
METHOD FOR REMOVING JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL 3425
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3427
REMOVE CONTROL VALVE ASSEMBLY 3427
INSTALL CONTROL VALVE ASSEMBLY 3435
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 3444
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 3444
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 3445
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 3449
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 3449
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 3449
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 3451
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 3451
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 3452
REMOVE AND INSTALL QUICK COUPLER VALVE 3454
WORK EQUIPMENT 3456
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3456
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3456
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3461
DISASSEMBLE AND ASSEMBLE STROKE SENSING BOOM CYLINDER ASSEMBLY 3468
METHOD FOR DISASSEMBLING STROKE SENSING BOOM CYLINDER ASSEMBLY 3469
METHOD FOR ASSEMBLING STROKE SENSING BOOM CYLINDER ASSEMBLY 3474
DISASSEMBLE AND ASSEMBLE STROKE SENSING ARM CYLINDER ASSEMBLY 3481
METHOD FOR DISASSEMBLING STROKE SENSING ARM CYLINDER ASSEMBLY 3482
METHOD FOR ASSEMBLING STROKE SENSING ARM CYLINDER ASSEMBLY 3487
DISASSEMBLE AND ASSEMBLE STROKE SENSING BUCKET CYLINDER ASSEMBLY 3495
METHOD FOR DISASSEMBLING STROKE SENSING BUCKET CYLINDER ASSEMBLY 3496
METHOD FOR ASSEMBLING STROKE SENSING BUCKET CYLINDER ASSEMBLY 3501
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3511
CAB AND ITS ATTACHMENTS 3517
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3517
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3517
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3528
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 3540
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 3542
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 3542
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 3552
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 3552
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 3555
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 3561
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 3561
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 3568
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3577
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3577
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3585
REMOVE AND INSTALL OPERATOR’S SEAT 3593
METHOD FOR REMOVING OPERATOR’S SEAT 3593
METHOD FOR INSTALLING OPERATOR’S SEAT 3595
REMOVE AND INSTALL SEAT BELT 3599
METHOD FOR REMOVING SEAT BELT 3599
METHOD FOR INSTALLING SEAT BELT 3599
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 3601
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 3601
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 3607
ELECTRICAL SYSTEM 3616
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3616
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3616
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3617
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 3619
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 3619
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 3623
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3629
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3629
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3631
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 3634
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 3634
METHOD FOR INSTALLING KomVision CONTROLLER 3635
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3637
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3637
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3640
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 3644
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 3644
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 3645
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3646
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3646
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3646
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3648
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3648
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3649
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3650
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3650
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3652
REMOVE AND INSTALL KomVision CAMERA 3655
METHOD FOR REMOVING KomVision CAMERA 3655
METHOD FOR INSTALLING KomVision CAMERA 3658
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3661
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3661
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3664
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3668
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3668
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3672
REMOVE AND INSTALL COMMUNICATION TERMINAL 3678
REMOVE COMMUNICATION TERMINAL 3678
INSTALL COMMUNICATION TERMINAL 3679
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3682
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 3682
INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3689
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY 3698
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY 3698
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY 3700
REMOVE AND INSTALL JUNCTION HARNESS OF CONTROL BOX 3704
METHOD FOR REMOVING JUNCTION HARNESS OF CONTROL BOX 3704
METHOD FOR INSTALLING JUNCTION HARNESS OF CONTROL BOX 3706
REMOVE AND INSTALL CONTROL BOX HARNESS 3709
METHOD FOR REMOVING CONTROL BOX HARNESS 3709
METHOD FOR INSTALLING CONTROL BOX HARNESS 3709
REMOVE AND INSTALL GNSS RECEIVER 3710
METHOD FOR REMOVING GNSS RECEIVER 3710
METHOD FOR INSTALLING GNSS RECEIVER 3710
REMOVE AND INSTALL NETWORK MODEM 3711
METHOD FOR REMOVING NETWORK MODEM 3711
METHOD FOR INSTALLING NETWORK MODEM 3711
REMOVE AND INSTALL NETWORK RADIO 3712
METHOD FOR REMOVING NETWORK RADIO 3712
METHOD FOR INSTALLING NETWORK RADIO 3714
REMOVE AND INSTALL GNSS RECEIVER ANTENNA 3717
REMOVE GNSS ANTENNA 3717
INSTALL GNSS ANTENNA 3718
REMOVE AND INSTALL NETWORK MODEM ANTENNA 3720
REMOVE NETWORK MODEM ANTENNA 3720
INSTALL NETWORK MODEM ANTENNA 3720
REMOVE AND INSTALL GNSS ANTENNA 3722
METHOD FOR REMOVING GNSS ANTENNA 3722
METHOD FOR INSTALLING GNSS ANTENNA 3723
REMOVE AND INSTALL IMU SENSOR 3725
METHOD FOR REMOVING IMU SENSOR 3725
METHOD FOR INSTALLING IMU SENSOR 3725
60 MAINTENANCE STANDARD 3727
CONTENTS 3728
ENGINE AND COOLING SYSTEM 3729
MAINTENANCE STANDARD OF ENGINE MOUNT 3729
MAINTENANCE STANDARD OF COOLING SYSTEM 3730
POWER TRAIN 3732
MAINTENANCE STANDARD OF SWING CIRCLE 3732
MAINTENANCE STANDARD OF SWING MACHINERY 3733
MAINTENANCE STANDARD OF FINAL DRIVE 3735
MAINTENANCE STANDARD OF SPROCKET 3737
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 3738
UNDERCARRIAGE AND FRAME 3740
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 3740
MAINTENANCE STANDARD OF IDLER 3742
MAINTENANCE STANDARD OF TRACK ROLLER 3744
MAINTENANCE STANDARD OF CARRIER ROLLER 3745
MAINTENANCE STANDARD OF TRACK SHOE 3746
MAINTENANCE STANDARD OF TRIPLE SHOE 3749
MAINTENANCE STANDARD OF SWAMP SHOE 3750
MAINTENANCE STANDARD OF ROAD LINER 3751
HYDRAULIC SYSTEM 3752
MAINTENANCE STANDARD OF HYDRAULIC TANK 3752
MAINTENANCE STANDARD OF MAIN PUMP 3753
MAINTENANCE STANDARD OF LS-EPC VALVE 3754
MAINTENANCE STANDARD OF PC-EPC VALVE 3755
MAINTENANCE STANDARD OF SWING MOTOR 3756
MAINTENANCE STANDARD OF TRAVEL MOTOR 3759
MAINTENANCE STANDARD OF CONTROL VALVE 3762
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3772
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3775
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3778
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3780
MAINTENANCE STANDARD OF SOLENOID VALVE 3781
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 3782
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 3784
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 3785
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 3786
WORK EQUIPMENT 3787
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3787
DIMENSION OF ARM 3792
DIMENSIONS OF BUCKET 3794
MAINTENANCE STANDARD OF BOOM CYLINDER 3796
MAINTENANCE STANDARD OF STROKE SENSING BOOM CYLINDER 3797
MAINTENANCE STANDARD OF STROKE SENSING ARM CYLINDER 3799
MAINTENANCE STANDARD OF STROKE SENSING BUCKET CYLINDER 3801
MAINTENANCE STANDARD OF STROKE SENSOR FOR BOOM CYLINDER 3803
MAINTENANCE STANDARD OF STROKE SENSOR FOR ARM CYLINDER 3804
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER 3805
80 APPENDIX 3807
CONTENTS 3808
AIR CONDITIONER SYSTEM 3810
PRECAUTIONS FOR REFRIGERANT 3810
AIR CONDITIONER COMPONENT 3811
SPECIFICATIONS OF AIR CONDITIONER 3813
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3814
OUTLINE OF REFRIGERATION CYCLE 3815
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3817
AIR CONDITIONER UNIT 3817
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3817
FUNCTION OF AIR CONDITIONER UNIT 3819
COMPONENT PARTS OF AIR CONDITIONER UNIT 3821
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3822
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3822
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3822
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3822
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3823
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3823
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3823
FUNCTION OF DUAL PRESSURE SWITCH 3824
AIR CONDITIONER CONTROLLER 3825
STRUCTURE OF AIR CONDITIONER CONTROLLER 3825
COMPRESSOR 3826
STRUCTURE OF COMPRESSOR 3826
SPECIFICATIONS OF COMPRESSOR 3826
FUNCTION OF COMPRESSOR 3826
CONDENSER 3827
STRUCTURE OF CONDENSER 3827
SPECIFICATIONS OF CONDENSER 3827
FUNCTION OF CONDENSER 3827
SENSORS FOR AIR CONDITIONER SYSTEM 3829
STRUCTURE OF SUNLIGHT SENSOR 3829
FUNCTION OF SUNLIGHT SENSOR 3829
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3829
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3829
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3831
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3833
AIR CONDITIONER SYSTEM DIAGRAM 3835
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3836
FUNCTION OF AIR CONDITIONER CONTROLLER 3837
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3838
TESTING AIR LEAKAGE (DUCT) 3842
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3842
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3844
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3845
TEST VENT (MODE) CHANGEOVER 3846
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3846
TESTING FRESH/RECIRC AIR CHANGEOVER 3848
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3848
TEST SUNLIGHT SENSOR 3849
METHOD FOR TESTING SUNLIGHT SENSOR 3849
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3850
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3850
TEST RELAYS 3851
METHOD FOR TESTING RELAYS 3851
AIR CONDITIONER TROUBLESHOOTING CHART 1 3852
AIR CONDITIONER TROUBLESHOOTING CHART 2 3853
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3856
FAILURE CODE [879AKA] 3858
FAILURE CODE [879AKB] 3859
FAILURE CODE [879BKA] 3860
FAILURE CODE [879BKB] 3862
FAILURE CODE [879CKA] 3864
FAILURE CODE [879CKB] 3865
FAILURE CODE [879DKZ] 3866
FAILURE CODE [879EMC] 3868
FAILURE CODE [879FMC] 3869
FAILURE CODE [879GKX] 3870
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3872
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3874
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3877
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3879
TROUBLESHOOTING USING GAUGE PRESSURE 3881
CONNECTION OF SERVICE TOOL 3884
METHOD FOR CONNECTING SERVICE TOOL 3884
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3886
HANDLE COMPRESSOR OIL 3888
METHOD FOR REPLACING DESICCANT 3890
90 CIRCUIT DIAGRAMS 3893
CONTENTS 3894
HYDRAULIC CIRCUIT DIAGRAM 3895
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3895
HYDRAULIC CIRCUIT DIAGRAM (1/3) 3899
HYDRAULIC CIRCUIT DIAGRAM (2/3) 3901
HYDRAULIC CIRCUIT DIAGRAM (3/3) 3903
ELECTRICAL CIRCUIT DIAGRAM 3905
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3905
ELECTRICAL CIRCUIT DIAGRAM (1/15) 3909
ELECTRICAL CIRCUIT DIAGRAM (2/15) 3911
ELECTRICAL CIRCUIT DIAGRAM (3/15) 3913
ELECTRICAL CIRCUIT DIAGRAM (4/15) 3915
ELECTRICAL CIRCUIT DIAGRAM (5/15) 3917
ELECTRICAL CIRCUIT DIAGRAM (6/15) 3919
ELECTRICAL CIRCUIT DIAGRAM (7/15) 3921
ELECTRICAL CIRCUIT DIAGRAM (8/15) 3923
ELECTRICAL CIRCUIT DIAGRAM (9/15) 3925
ELECTRICAL CIRCUIT DIAGRAM (10/15) 3927
ELECTRICAL CIRCUIT DIAGRAM (11/15) 3929
ELECTRICAL CIRCUIT DIAGRAM (12/15) 3931
ELECTRICAL CIRCUIT DIAGRAM (13/15) 3933
ELECTRICAL CIRCUIT DIAGRAM (14/15) 3935
ELECTRICAL CIRCUIT DIAGRAM (15/15) 3937
INDEX 3939

DESCRIPTION:

Komatsu PC210LCI -11E0 Hydraulic Excavator Shop Manual UENBM00570 – PDF DOWNLOAD 

SERIAL NUMBERS K77001 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.

S.V 26/12/24