Komatsu PC2000-8 Galeo Hydraulic Excavator Service Repair Shop Manual (20001 and up) - SEN01607-06

This Complete Service Repair Workshop Manual PDF Download for the PC2000-8 Galeo Komatsu Hydraulic Excavator Mining Shovels (S/N: 20001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC2000-8
S/N : 20001 and up
Mining Shovels


TABLE OF CONTENTS :

00 INDEX AND FOREWORD
01 SPECIFICATION
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
90 DIAGRAMS AND DRAWINGS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN01607-06
Total Pages : 1387


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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00 INDEX AND FOREWORD
INDEX
COMPOSITION OF SHOP MANUAL
TABLE OF CONTENTS
FOREWORD AND GENERAL INFORMATION
SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES
HOW TO READ ELECTRIC WIRE CODE
PRECAUTIONS WHEN CARRYING OUT OPERATION
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

01 SPECIFICATION
SPECIFICATION AND TECHNICAL DATA
SPECIFICATION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
RADIATOR AND OIL COOLER
PTO
PTO LUBRICATION SYSTEM
POWER TRAIN
POWER TRAIN
SWING MACHINERY
SWING CIRCLE
FINAL DRIVE
SPROCKET
UNDERCARRIAGE AND FRAME
TRACK FRAME
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
HIC SYSTEM
HYDRAULIC SYSTEM, PART 1
HYDRAULIC PIPING DRAWING
HYDRAULIC TANK
OIL COOLER
LINE OIL FILTER
PILOT OIL FILTER
RETURN OIL FILTER
MOTOR DRAIN OIL FILTER
PUMP DRAIN FILTER
ACCUMULATOR
TRAVEL JUNCTION VALVE
SOLENOID VALVE
HYDRAULIC CYLINDER
GREASING SYSTEM
CENTER SWIVEL JOINT
HYDRAULIC SYSTEM, PART 2
CONTROL VALVE
ELECTRONIC OLSS SYSTEM
SWING MOTOR
COOLING FAN MOTOR (FOR RADIATOR AND OIL COOLER)
COOLING FAN PUMP
HYDRAULIC SYSTEM, PART 3
TRAVEL MOTOR
HYDRAULIC PUMP
PPC VALVE
VARIABLE BACK PRESSURE VALVE
SUCTION SELECTOR VALVE
PPC CUT-OFF VALVE
WORK EQUIPMENT
WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT
CAB AND ITS ATTACHMENTS
AIR CONDITIONER PIPING
CAB
ELECTRICAL SYSTEM
ENGINE CONTROL
ELECTRICAL CONTROL SYSTEM
MONITOR SYSTEM
SENSOR
ORBCOMM TERMINAL

20 STANDARD VALUE TABLE
STANDARD SERVICE VALUE TABLE
STANDARD SERVICE VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
STANDARD SERVICE VALUE TABLE FOR CHASSIS

30 TESTING AND ADJUSTING
TESTING AND ADJUSTING, PART 1
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
TESTING AIR BOOST PRESSURE
TESTING EXHAUST TEMPERATURE
TESTING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
TESTING COMPRESSION PRESSURE
TESTING BLOW-BY PRESSURE
TESTING ENGINE OIL PRESSURE
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM
TESTING FUEL PRESSURE
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR
BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT (LOW-GRADE FUEL SPECIFICATION)
TESTING FUEL SYSTEM FOR LEAKAGE
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AND ADJUSTING, PART 2
TESTING SWING CIRCLE BEARING CLEARANCE
REMAINING PRESSURE RELIEF FROM HIC CIRCUIT
GAS FILLING IN HIC CIRCUIT ACCUMULATOR
BLEEDING AIR FROM HIC CIRCUIT AND SUPPLYING OIL TO IT
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURES
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE (OUTPUT PRESSURE OF SELF PRESSURE REDUCING VALVE)
TESTING AND ADJUSTING MAIN PUMP CONTROL SIGNAL
MEASURING FAN SPEED
MEASURING FAN PUMP EPC SOLENOID CURRENT
MEASURING FAN PUMP EPC SOLENOID VALVE OUTPUT PRESSURE
OIL PRESSURE MEASURING POINTS FOR PUMP DISCHARGE PRESSURE OR JET SENSOR DIFFERENTIAL PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTLET PRESSURE
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE
TESTING AND ADJUSTING TRAVEL DEVIATION
TESTING WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION
TESTING OIL LEAKAGE
REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT
AIR BLEEDING FROM EACH COMPONENT
AIR BLEEDING FROM PPC CIRCUIT
TESTING AND ADJUSTING AUTO GREASE SYSTEM
ADJUSTING MIRRORS
TESTING AND ADJUSTING, PART 3
SPECIAL FUNCTIONS OF MACHINE MONITOR
HANDLING CONTROLLER VOLTAGE CIRCUIT
TESTING AND ADJUSTING, PART 4
VHMS CONTROLLER INITIAL SETTING PROCEDURE
PRECAUTIONS FOR REPLACING VHMS CONTROLLER
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
PM-CLINIC SERVICE
MEASUREMENT PROCEDURE

40 TROUBLESHOOTING
FAILURE CODE TABLE AND FUSE LOCATIONS
FAILURE CODE TABLE
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER BOX AND T-ADAPTER TABLE
TROUBLESHOOTING BY FAILURE CODE, PART 1
FAILURE CODE [0410KA] FUEL LV. SENSOR FAILURE
FAILURE CODE [0410KB] FUEL LV. SENSOR FAILURE
FAILURE CODE [6014NX] HYDRAULIC OIL FILTER CLOGGING (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 51)
FAILURE CODE [8800ZG] AUTO GREASE ABNORMALLY
FAILURE CODE [7@HAZL] VR1/P1F RELIEF PRESS ABNORMALITY
FAILURE CODE [7@HBZL] VL1/P1R RELIEF PRESS ABNORMALITY
FAILURE CODE [7@HCZL] VR2/P2F RELIEF PRESS ABNORMALITY
FAILURE CODE [7@HDZL] VL2/P2R RELIEF PRESS ABNORMALITY
FAILURE CODE [AA10NX] AIRCLEANER CLOGGING
FAILURE CODE [AB00KE] CHARGE VOLTAGE LOW
FAILURE CODE [aB00KE] LOW UPPER ALR CHARGE VOLTAGE (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 11)
FAILURE CODE [B@BAZG] ENG. OIL PRESS. LOW
FAILURE CODE [B@BAZK] ENG. OIL LEVEL LOW
FAILURE CODE [B@BCNS] ENG. WATER OVERHEAT
FAILURE CODE [B@BCZK] ENG. WATER LVL LOW
FAILURE CODE [B@CBNS] PTO OIL OVERHEAT (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 61)
FAILURE CODE [B@HANS] HYDR. OIL OVERHEAT
FAILURE CODE [B@HAZK] LOW HYDRAULIC OIL LEVEL (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 52)
FAILURE CODE [CA111] ECM CRITICAL INTERNAL FAILURE
FAILURE CODE [CB111] ECM CRITICAL INTERNAL FAILURE
FAILURE CODE [CA115] ENG. NE AND BKUP SPEED SENS ERROR
FAILURE CODE [CB115] ENG. NE AND BKUP SPEED SENS ERROR
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR
FAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERROR
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR
FAILURE CODE [CA135] ENG OIL PRESS SENSOR HIGH ERROR
FAILURE CODE [CA141] ENG OIL PRESS SENSOR LOW ERROR
FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERROR
FAILURE CODE [CA145] COOLANT TEMP SENS LOW ERROR
FAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERROR
FAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERROR
FAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERROR
FAILURE CODE [CB187] SENS SUPPLY 2 VOLT LOW ERROR
FAILURE CODE [CA212] ENG OIL TEMP SENSOR HIGH ERROR
FAILURE CODE [CA213] ENG OIL TEMP SENSOR LOW ERROR
TROUBLESHOOTING BY FAILURE CODE, PART 2
FAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERROR
FAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERROR
FAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR
FAILURE CODE [CB227] SENS SUPPLY 2 VOLT HIGH ERROR
FAILURE CODE [CA234] ENG OVER SPEED
FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERROR
FAILURE CODE [CB238] NE SPEED SENS SUPPLY VOLT ERROR
FAILURE CODE [CA263] FUEL TEMP SENSOR HIGH ERROR
FAILURE CODE [CB263] FUEL TEMP SENSOR HIGH ERROR
FAILURE CODE [CA265] FUEL TEMP SENSOR LOW ERROR
FAILURE CODE [CB265] FUEL TEMP SENSOR LOW ERROR
FAILURE CODE [CA271] IMV/PCV1 SHORT ERROR
FAILURE CODE [CB271] IMV/PCV1 SHORT ERROR
FAILURE CODE [CA272] IMV/PCV1 OPEN ERROR
FAILURE CODE [CB272] IMV/PCV1 OPEN ERROR
FAILURE CODE [CA273] PCV2 SHORT ERROR
FAILURE CODE [CB273] PCV2 SHORT ERROR
FAILURE CODE [CA274] PCV2 OPEN ERROR
FAILURE CODE [CB274] PCV2 OPEN ERROR
FAILURE CODE [CA322] INJ #1(L#1) OPEN/SHORT ERROR
FAILURE CODE [CA323] INJ #5(L#5) OPEN/SHORT ERROR
FAILURE CODE [CA324] INJ #3(L#3) OPEN/SHORT ERROR
FAILURE CODE [CA325] INJ #6(L#6) OPEN/SHORT ERROR
FAILURE CODE [CA331] INJ #2(L#2) OPEN/SHORT ERROR
FAILURE CODE [CA332] INJ #4(L#4) OPEN/SHORT ERROR
FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITY
FAILURE CODE [CB342] CALIBRATION CODE INCOMPATIBILITY
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR
FAILURE CODE [CB351] INJECTORS DRIVE CIRCUIT ERROR
FAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERROR
FAILURE CODE [CB352] SENS SUPPLY 1 VOLT LOW ERROR
FAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERROR
FAILURE CODE [CB386] SENS SUPPLY 1 VOLT HIGH ERROR
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR
FAILURE CODE [CB441] BATTERY VOLTAGE LOW ERROR
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR
FAILURE CODE [CB442] BATTERY VOLTAGE HIGH ERROR
FAILURE CODE [CA449] RAIL PRESS VERY HIGH ERROR
FAILURE CODE [CB449] RAIL PRESS VERY HIGH ERROR
TROUBLESHOOTING BY FAILURE CODE, PART 3
FAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERROR
FAILURE CODE [CB451] RAIL PRESS SENSOR HIGH ERROR
FAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERROR
FAILURE CODE [CB452] RAIL PRESS SENSOR LOW ERROR
FAILURE CODE [CA553] RAIL PRESS HIGH ERROR
FAILURE CODE [CB553] RAIL PRESS HIGH ERROR
FAILURE CODE [CA554] RAIL PRESS SENSOR IN RANGE ERROR
FAILURE CODE [CB554] RAIL PRESS SENSOR IN RANGE ERROR
FAILURE CODE [CA559] RAIL PRESS LOW ERROR
FAILURE CODE [CB559] RAIL PRESS LOW ERROR
FAILURE CODE [CA689] ENG NE SPEED SENSOR ERROR
FAILURE CODE [CB689] ENG NE SPEED SENSOR ERROR
FAILURE CODE [CA691] INTAKE AIR TEMP SENS HIGH ERROR
FAILURE CODE [CA692] INTAKE AIR TEMP SENS LOW ERROR
FAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR
FAILURE CODE [CB731] ENG BKUP SPEED SENS PHASE ERROR
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR
FAILURE CODE [CB757] ALL PERSISTENT DATA LOST ERROR
FAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR
FAILURE CODE [CB778] ENG BKUP SPEED SENSOR ERROR
FAILURE CODE [CA781] CEN COMMUNICATION ERROR
FAILURE CODE [CB781] CEN COMMUNICATION ERROR
FAILURE CODE [CA1117] PERSISTENT DATA LOST ERROR
FAILURE CODE [CB1117] PERSISTENT DATA LOST ERROR
FAILURE CODE [CA1257] HARNESS KEY ERROR
FAILURE CODE [CB1257] HARNESS KEY ERROR
FAILURE CODE [CB1548] INJ #7(R#1) OPEN/SHORT ERROR
FAILURE CODE [CB1549] INJ #8(R#2) OPEN/SHORT ERROR
FAILURE CODE [CB1551] INJ #10(R#4) OPEN/SHORT ERROR
FAILURE CODE [CB1552] INJ #11(R#5) OPEN/SHORT ERROR
FAILURE CODE [CB1553] INJ #12(R#6) OPEN/SHORT ERROR
FAILURE CODE [CB1622] INJ #9(R#3) OPEN/SHORT ERROR
FAILURE CODE [CA1633] KOMNET DATA LINK TIME OUT ERROR
FAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR
FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERROR
FAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR
FAILURE CODE [CB2249] RAIL PRESS VERY LOW ERROR
FAILURE CODE [CA2555] GRID HEATER RELAY VOLT LOW ERROR
FAILURE CODE [CA2556] GRID HEATER RELAY VOLT HIGH ERROR
TROUBLESHOOTING BY FAILURE CODE, PART 4
FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/C
FAILURE CODE [D163KB] FLASH LIGHT RELAY S/C
FAILURE CODE [D195KA] STEP LIGHT RELAY DISC
FAILURE CODE [D195KY] STEP LIGHT RELAY S/C
FAILURE CODE [D1E9KB] WIPER DRIVE RELAY 1 S/C
FAILURE CODE [D1EAKB] WIPER DRIVE RELAY 2 S/C
FAILURE CODE [D1EBKB] LOWER WIPER BRAKE RELAY SHORT CIRCUIT
FAILURE CODE [D1ECKB] UPPER WIPER BRAKE RELAY SHORT CIRCUIT
FAILURE CODE [DA22KK] PUMP 1 SOLENOID POWER LOW ERROR
FAILURE CODE [dA22KK] PUMP 2 SOLENOID POWER LOW ERROR
FAILURE CODE [DA25KP] PUMP 1 SENS SUPPLY VOL LOW ERROR
FAILURE CODE [dA25KP] PUMP 2 SENS SUPPLY VOL LOW ERROR
FAILURE CODE [DA26KP] 5V SENSOR 2 POWER ABNORMALITY
FAILURE CODE [DA29KQ] PUMP 1 MODEL SELECT ABNORMALITY
FAILURE CODE [dA29KQ] PUMP 2 MODEL SELECT ABNORMALITY
FAILURE CODE [DA2RMC] CAN DISCON (PUMP 1 CON DETECTED)
FAILURE CODE [dA2RMC] CAN DISCON (PUMP 2 CON DETECTED)
FAILURE CODE [DA2TMC] PUMP COMM. ECM CHILD ABNORMALITY
FAILURE CODE [DBB0KK] VHMS SOURCE VOLTAGE ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 01)
FAILURE CODE [DBB0KQ] VHMS CONNECTOR MISMATCH (OR CHANGE OF VHMS-LED DISPLAY FROM nF TO 11)
FAILURE CODE [DBB5KP] VHMS 5V SOURCE SYS ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 04)
FAILURE CODE [DBB6KP] VHMS 24V SOURCE SYS ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n9 TO 02)
FAILURE CODE [DBBQKR] KOM-NET/C ERROR (OR CHANGE OF VHMS-LED DISPLAY FROM n8 TO 02)
FAILURE CODE [DGE5KX] AMBIENT AIR TEMP SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n4 TO 01)
FAILURE CODE [DGH2KB] HYDR. OIL TEMP. SENSOR S/C
FAILURE CODE [DGT3KZ] PTO TEMP SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 01)
TROUBLESHOOTING BY FAILURE CODE, PART 5
FAILURE CODE [DGT5KA] EXHAUST TEMP. SENSOR LBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 12)
FAILURE CODE [dGT5KA] EXHAUST TEMP. SENSOR LBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 22)
FAILURE CODE [DGT5KB] EXHAUST TEMP. SENSOR LBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 11)
FAILURE CODE [dGT5KB] EXHAUST TEMP. SENSOR LBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 21)
FAILURE CODE [DGT6KA] EXHAUST TEMP. SENSOR RBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 24)
FAILURE CODE [dGT6KA] EXHAUST TEMP. SENSOR RBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 26)
FAILURE CODE [DGT6KB] EXHAUST TEMP. SENSOR RBF FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 23)
FAILURE CODE [dGT6KB] EXHAUST TEMP. SENSOR RBR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM N3 TO 26)
FAILURE CODE [DH25KX] VR1/P1F J/S DIF PRESS SENSOR ABNORMALITY
FAILURE CODE [DH26KX] VL1/P1R J/S DIF PRESS SENSOR ABNORMALITY
FAILURE CODE [DH27KX] VR2/P2F J/S DIF PRESS SENSOR ABNORMALITY
FAILURE CODE [DH28KX] VL2/P2R J/S DIF PRESS SENSOR ABNORMALITY
FAILURE CODE [DHE5KB] BLOWBY PRES. SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 32)
FAILURE CODE [DHE5KY] BLOWBY PRES. SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 31)
FAILURE CODE [DHH2KA] HYDRAULIC OIL FILTER SENSOR FAILURE (OR CHANGE OF VHMS-LED DISPLAY FROM n5 TO 53)
FAILURE CODE [DHPEKX] VR1/P1F PUMP P. SENSOR ABNORMALITY
FAILURE CODE [DHPFKX] VL1/P1R PUMP P. SENSOR ABNORMALITY
FAILURE CODE [DHPGKX] VR2/P2F PUMP P. SENSOR ABNORMALITY
FAILURE CODE [DHPHKX] VL2/P2R PUMP P. SENSOR ABNORMALITY
FAILURE CODE [DHPSKX] AUTO GREASE PRESS SENSOR ABNORMALITY
FAILURE CODE [DHPTKX] FAN(RAD) PUMP P. SENSOR OPEN CIRCUIT
FAILURE CODE [DHPUKX] FAN(O/C) PUMP P. SENSOR OPEN CIRCUIT
FAILURE CODE [DHS3KX] ARM DIG PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHS4KX] BUCKET CURL PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHS8KX] BOOM RAISE PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHS9KX] BOOM LOWER PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHSAKX] SWING RIGHT PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHSBKX] SWING LEFT PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHSCKX] ARM DUMP PPC PRESS SENSOR ABNORMALITY
FAILURE CODE [DHSDKX] BUCKET DUMP PPC PRESS SENSOR ABNORMALITY
TROUBLESHOOTING BY FAILURE CODE, PART 6
FAILURE CODE [DUM3KB] AUTO GREASE CAUTION LED SHORT CIRCUIT
FAILURE CODE [DUM4KB] FAN REVERSE LED SHORT CIRCUIT
FAILURE CODE [DV20KB] TRAVEL ALARM S/C
FAILURE CODE [DW41KA] SWING PRIORITY SOL OPEN CIRCUIT
FAILURE CODE [DW41KB] SWING PRIORITY SOL SHORT CIRCUIT
FAILURE CODE [DW45KA] SWING BRAKE SOL. DISC
FAILURE CODE [DW45KB] SWING BRAKE SOL. S/C
FAILURE CODE [DW91KA] STRAIGHT-TRAVEL SOL. DISC
FAILURE CODE [DW91KB] STRAIGHT-TRAVEL SOL. S/C
FAILURE CODE [DW4XKA] BUCKET CURL HI CANCEL SOL. DISC.
FAILURE CODE [DW4XKB] BUCKET CURL HI CANCEL SOL. S/C
FAILURE CODE [DW7BKA] FAN MOTOR (RAD) REVERSE SOL OPEN CIRCUIT
FAILURE CODE [DW7BKB] FAN REVERSE SOL. S/C
FAILURE CODE [DW7HKA] FAN MOTOR(O/C) REVERSE SOL OPEN CIRCUIT
FAILURE CODE [DW7HKB] FAN MOTOR(O/C) REVERSE SOL SHORT CIRCUIT
FAILURE CODE [DWA3KA] ARM THROTTLE VALVE/L SOL OPEN CIRCUIT
FAILURE CODE [DWA3KB] ARM THROTTLE VALVE/L SOL SHORT CIRCUIT
FAILURE CODE [DWA4KA] ARM THROTTLE VALVE/R SOL OPEN CIRCUIT
FAILURE CODE [DWA4KB] ARM THROTTLE VALVE/R SOL SHORT CIRCUIT
FAILURE CODE [DWA5KA] AUTO GREASE SOL OPEN CIRCUIT
FAILURE CODE [DWA5KB] AUTO GREASE SOL SHORT CIRCUIT
FAILURE CODE [DWA6KA] BOOM THROTTLE VALVE SOL OPEN CIRCUIT
FAILURE CODE [DWA6KB] BOOM THROTTLE VALVE SOL SHORT CIRCUIT
FAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC.
FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/C
FAILURE CODE [DWK2KA] BACK PRESS COMP VALVE SOL OPEN CIRCUIT
FAILURE CODE [DWK2KB] BACK PRESS COMP VALVE SOL SHORT CIRCUIT
TROUBLESHOOTING BY FAILURE CODE, PART 7
FAILURE CODE [DWN5KA] FAN (RAD) PUMP EPC SOL OPEN CIRCUIT
FAILURE CODE [DWN5KB] FAN (RAD) PUMP EPC SOL SHORT CIRCUIT
FAILURE CODE [DWNCKA] FAN (O/C) PUMP EPC SOL OPEN CIRCUIT
FAILURE CODE [DWNCKB] FAN (O/C) PUMP EPC SOL SHORT CIRCUIT
FAILURE CODE [DXAAKA] P1F EPC SOL DISC
FAILURE CODE [DXAAKB] P1F EPC SOL S/C
FAILURE CODE [DXABKA] P1R PUMP EPC SOL. DISC.
FAILURE CODE [DXABKB] P1R PUMP EPC SOL. S/C
FAILURE CODE [DXACKA] P2F PUMP EPC SOL. DISC.
FAILURE CODE [DXACKB] P2F PUMP EPC SOL. S/C
FAILURE CODE [DXADKA] P2R PUMP EPC SOL. DISC.
FAILURE CODE [DXADKB] P2R PUMP EPC SOL. S/C
FAILURE CODE [DY2CKB] WASHER DRIVE S/C
FAILURE CODE [DY20MA] LOW WIPER WORKING ABNORMALITY
FAILURE CODE [DY2FMA] UPPER WIPER WORKING ABNORMALITY
FAILURE CODE [F@BBZL] HIGH BLOWBY PRESSURE (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 38)
FAILURE CODE [F@BYNR] VERY HIGH LBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 62)
FAILURE CODE [f@BYNR] VERY HIGH LBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 72)
FAILURE CODE [F@BYNS] HIGH LBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 61)
FAILURE CODE [f@BYNS] HIGH LBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 71)
FAILURE CODE [F@BZNR] VERY HIGH RBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 82)
FAILURE CODE [f@BZNR] VERY HIGH RBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 92)
FAILURE CODE [F@BZNS] HIGH RBF CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 81)
FAILURE CODE [f@BZNS] HIGH RBR CYL EXHAUST TEMP (OR CHANGE OF VHMS-LED DISPLAY FROM n3 TO 91)
FAILURE CODE [LA10ZL] RAD SYSTEM FAN PUMP RELIEF PRESSURE HIGH ERROR
FAILURE CODE [LA20ZL] O/C SYSTEM PUMP RELIEF PRESSURE HIGH ERROR
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
CONTENTS OF TROUBLESHOOTING TABLE
E-1 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR DISPLAYS NOTHING
E-2 WHEN STARTING SWITCH TURNED ON (BEFORE STARTING ENGINE), BASIC CHECK ITEM LIGHTS UP
E-3 ENGINE DOES NOT START (ENGINE DOES NOT TURN)
E-4 AUTO-DECELERATOR DOES NOT OPERATE
E-5 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE
E-6 PREHEATER DOES NOT WORK
E-7 WHOLE WORK EQUIPMENT, SWING OPERATION AND MACHINE TRAVEL OPERATION ARE DISABLED
E-8 MACHINE PUSH-UP FUNCTION DOES NOT WORK
E-9 BOOM SHOCKLESS FUNCTION CANNOT BE RELEASED
E-10 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS
E-11 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-14 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY
E-15 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY
E-16 MACHINE MONITOR DISPLAY ANYTHING EVEN WHEN OPERATED ON MONITOR SWITCH SECTION
E-17 WIPER DOES NOT WORK
E-18 MONITORING FUNCTION DOES NOT DISPLAY "TRAVEL" NORMALLY
E-19 TRAVEL ALARM DOES NOT SOUND
E-20 ALL OF ROOM LAMP, HEADLAMP AND WORKING LAMP DO NOT LIGHT UP
E-21 AIR CONDITIONER DOES NOT WORK
E-22 STEP LIGHT DOES NOT LIGHT UP OR GOES OFF
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS
TABLE OF FAILURE MODES AND CAUSES
INFORMATION IN TROUBLESHOOTING TABLE
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, AND SWING IS LOW
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS
H-3 WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE
H-4 ABNORMAL NOISE COMES FROM AROUND HYDRAULIC PUMP
H-5 SPEED OR POWER OF BOOM IS LOW
H-6 SPEED OR POWER OF ARM IS LOW
H-7 SPEED OR POWER OF BUCKET IS LOW
H-8 BOOM DOES NOT MOVE
H-9 ARM DOES NOT MOVE
H-10 BUCKET DOES NOT MOVE
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE.
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE
H-13 HEAVY LIFT FUNCTION DOES NOT WORK OR IS NOT RESET.
H-14 MACHINE PUSH-UP FUNCTION DOES NOT WORK OR IS NOT RESET
H-15 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR IS NOT RESET
H-16 MACHINE GRADUALLY DEVIATES DURING TRAVELING
H-17 MACHINE DEVIATES EXCESSIVELY WHEN STARTED TO TRAVEL
H-18 MACHINE DEVIATES EXCESSIVELY DURING MULTIPLE OPERATIONS
H-19 TRAVELING SPEED OR POWER IS LOW
H-20 TRAVEL SYSTEM DOES NOT MOVE (ONLY ONE SIDE)
H-21 UPPER STRUCTURE DOES NOT SWING
H-22 SWING SPEED OR ACCELERATION IS LOW
H-23 IN COMPOUND OPERATION OF WORK EQUIPMENT, SWING SPEED OR ACCELERATION IS LOW
H-24 UPPER STRUCTURE OVERRUNS REMARKABLY WHEN IT STOPS SWINGING
H-25 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING
H-26 LARGE ABNORMAL SOUND COMES FROM WHEN UPPER STRUCTURE STOPS SWINGING
H-27 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE IN SWING OPERATION
H-28 FAN ROTATION IS ABNORMAL (LARGE NOISE OR VIBRATION OF FANS, OR FAN OVERHEATING)
TROUBLESHOOTING OF MECHANICAL SYSTEM (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
S-12 OIL PRESSURE DROPS
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE

50 DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
ENGINE AND COOLING SYSTEM (12V140E-3)
REMOVAL AND INSTALLATION OF POWER CONTAINER ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
ENGINE (12V140E-3)
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
POWER TRAIN
REMOVAL AND INSTALLATION OF PTO ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
UNDERCARRIAGE AND FRAME
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUST CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY
REMOVAL AND INSTALLATION OF ARM CYLINDER
REMOVAL AND INSTALLATION OF ARM ASSEMBLY
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVAL AND INSTALLATION OF OPERATOR CAB ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATOR CAB GLASS (ADHESION GLASS)
REMOVAL AND INSTALLATION OF OPERATOR CAB (ASSEMBLY-TYPE)
REMOVAL AND INSTALLATION OF CAB BASE ASSEMBLY
ELECTRICAL SYSTEM
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF VHMS CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF ORBCOMM TERMINAL ASSEMBLY FOR VHMS

90 DIAGRAMS AND DRAWINGS
HYDRAULIC DIAGRAMS AND DRAWINGS
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL DIAGRAMS AND DRAWINGS
ELECTRICAL CIRCUIT DIAGRAM (1/2)
ELECTRICAL CIRCUIT DIAGRAM (2/2)
CONNECTOR ARRANGEMENT DIAGRAM

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