Komatsu PC2000-8 Hydraulic Excavator Service Repair Manual (SN 20001 and up)

SEN01607-08

HYDRAULIC EXCAVATOR

PC2000-8 SERIAL NUMBERS

20001

and up

SEN01609-08

00 Index and foreword

Table of contents

1

00 Index and foreword Index SEN01609-08 Composition of shop manual ...................................................................................................

2 Table of contents......................................................................................................................

4 Foreword and general information SEN01610-03 Safety notice ............................................................................................................................

2 How to read the shop manual..................................................................................................

7 Explanation of terms for maintenance standard ......................................................................

9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN01612-02 Specification drawings .............................................................................................................

2 Specifications...........................................................................................................................

6 Weight table ............................................................................................................................. 10 Table of fuel, coolant and lubricants ........................................................................................ 16 10 Structure, function and maintenance standard Engine and cooling system SEN01614-00 Engine and cooling system .........................................................................................................

2 Radiator and oil cooler.............................................................................................................

2 PTO .........................................................................................................................................

4 PTO lubrication system............................................................................................................

6 Power train SEN01615-00 Power train ..................................................................................................................................

2 Power train...............................................................................................................................

2 Swing machinery .....................................................................................................................

3 Swing circle..............................................................................................................................

6 Final drive ................................................................................................................................

8 Sprocket................................................................................................................................... 11 Undercarriage and frame SEN01616-00 Undercarriage and frame ............................................................................................................

2 Track frame..............................................................................................................................

2 Idler..........................................................................................................................................

4 Carrier roller.............................................................................................................................

6 Track roller ...............................................................................................................................

7 Track shoe ...............................................................................................................................

8 HIC system .............................................................................................................................. 13

4

PC2000-8

00 Index and foreword

SEN01609-08

Hydraulic system, Part 1 SEN01618-03 Hydraulic piping drawing .........................................................................................................

4 Hydraulic tank..........................................................................................................................

8 Oil cooler ................................................................................................................................. 10 Line oil filter ............................................................................................................................. 12 Pilot oil filter ............................................................................................................................. 13 Return oil filter ......................................................................................................................... 14 Motor drain oil filter .................................................................................................................. 15 Pump drain filter ...................................................................................................................... 16 Accumulator............................................................................................................................. 17 Travel junction valve ................................................................................................................ 19 Solenoid valve ......................................................................................................................... 22 Hydraulic cylinder .................................................................................................................... 30 Greasing system...................................................................................................................... 34 Center swivel joint ................................................................................................................... 44 Hydraulic ladder system .......................................................................................................... 45 Hydraulic system, Part 2 SEN01619-01 Hydraulic system, Part 2 .............................................................................................................

2 Control valve............................................................................................................................

2 Electronic OLSS system.......................................................................................................... 30 Swing motor............................................................................................................................. 34 Cooling fan motor (For radiator and oil cooler)........................................................................ 42 Cooling fan pump .................................................................................................................... 48 Hydraulic system, Part 3 SEN01620-01 Hydraulic system, Part 3 .............................................................................................................

2 Travel motor.............................................................................................................................

2 Hydraulic pump........................................................................................................................ 14 PPC valve................................................................................................................................ 32 Variable back pressure valve................................................................................................... 44 Suction selector valve.............................................................................................................. 48 PPC cut-off valve ..................................................................................................................... 52 Work equipment SEN01621-02 Work equipment ......................................................................................................................

2 Dimensions of work equipment ...............................................................................................

6 Cab and its attachments SEN01622-00 Cab and its attachments..............................................................................................................

2 Air conditioner piping ...............................................................................................................

2 Cab ..........................................................................................................................................

3 Electrical system SEN01623-01 Electrical system .........................................................................................................................

2 Engine control..........................................................................................................................

2 Electrical control system.......................................................................................................... 13 Monitor system ........................................................................................................................ 55 Sensor ..................................................................................................................................... 83 ORBCOMM terminal................................................................................................................ 95

PC2000-8

5

SEN01609-08

00 Index and foreword

20 Standard value table Standard service value table SEN02006-01 Standard service value table .......................................................................................................

2 Standard service value table for testing, adjusting, and troubleshooting .................................

2 Standard service value table for chassis (Backhoe specification) ...........................................

3 Standard service value table for chassis (Loading shovel specification) ................................. 14 30 Testing and adjusting Testing and adjusting, Part 1 SEN02007-01 Testing and adjusting, Part 1 .......................................................................................................

3 Tools for testing, adjusting, and troubleshooting......................................................................

3 Measuring engine speed .........................................................................................................

6 Testing air boost pressure........................................................................................................

7 Testing exhaust temperature ...................................................................................................

8 Testing exhaust color ...............................................................................................................

9 Adjusting valve clearance ........................................................................................................ 11 Testing compression pressure ................................................................................................. 13 Testing blow-by pressure ......................................................................................................... 15 Testing engine oil pressure ...................................................................................................... 16 Handling fuel system parts ...................................................................................................... 17 Releasing residual pressure in fuel system ............................................................................. 17 Testing fuel pressure................................................................................................................ 18 Testing leakage from pressure limiter and return rate from injector......................................... 19 Bleeding air from fuel circuit .................................................................................................... 22 Bleeding air from fuel circuit (low-grade fuel specification)...................................................... 26 Testing fuel system for leakage ............................................................................................... 28 Testing and adjusting air conditioner compressor belt tension ................................................ 30 Testing and adjusting, Part 2 SEN02008-01 Testing and adjusting, Part 2 .......................................................................................................

3 Testing swing circle bearing clearance ....................................................................................

3 Remaining pressure relief from HIC circuit ..............................................................................

4 Gas filling in HIC circuit accumulator .......................................................................................

5 Bleeding air from HIC circuit and supplying oil to it .................................................................

6 Testing and adjusting track shoe tension.................................................................................

8 Testing and adjusting work equipment, swing and travel circuit oil pressures......................... 11 Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve) ............................................................ 15 Testing and adjusting main pump control signal ...................................................................... 17 Measuring fan speed ............................................................................................................... 20 Measuring fan pump EPC solenoid current ............................................................................. 21 Measuring fan pump EPC solenoid valve output pressure...................................................... 22 Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure ......................................................................................... 24 Measuring PPC valve output pressure .................................................................................... 25 Measuring solenoid valve outlet pressure ............................................................................... 30 Adjusting work equipment and swing PPC valve..................................................................... 32 Testing and adjusting travel deviation...................................................................................... 33 Testing work equipment hydraulic drift cause portion .............................................................. 35 Testing oil leakage ................................................................................................................... 36 Remaining pressure relief from hydraulic circuit...................................................................... 39 Air bleeding from each component .......................................................................................... 40 Air bleeding from PPC circuit................................................................................................... 45 Testing and adjusting auto grease system............................................................................... 47 Adjusting mirrors...................................................................................................................... 50 Testing and adjusting clearance of hydraulic ladder proximity switch...................................... 52 Testing and adjusting position of hydraulic ladder position sensor plate ................................. 54

6

PC2000-8

00 Index and foreword

SEN01609-08

Testing and adjusting, Part 3 SEN02009-01 Testing and adjusting, Part 3.......................................................................................................

2 Special functions of machine monitor ......................................................................................

2 Handling controller voltage circuit............................................................................................ 57 Testing and adjusting, Part 4 SEN02010-00 Testing and adjusting, Part 4.......................................................................................................

2 VHMS controller initial setting procedure ................................................................................

2 Precautions for replacing VHMS controller.............................................................................. 19 Preparation work for troubleshooting of electrical system ....................................................... 25 Pm-clinic service...................................................................................................................... 27 Measurement procedure ......................................................................................................... 28 40 Troubleshooting Failure code table and fuse locations SEN02011-00 Failure code table and fuse locations..........................................................................................

2 Failure code table ....................................................................................................................

2 Before carrying out troubleshooting of electrical system .........................................................

9 General information on troubleshooting SEN02012-01 General information on troubleshooting ......................................................................................

2 Points to remember when troubleshooting ..............................................................................

2 Sequence of events in troubleshooting ...................................................................................

3 Checks before troubleshooting................................................................................................

4 Classification and procedures of troubleshooting....................................................................

5 Connection table for connector pin numbers ...........................................................................

9 T- branch box and T- branch adapter table ............................................................................. 45 Troubleshooting by failure code, Part 1 SEN02096-01 Troubleshooting by failure code, Part 1.......................................................................................

4 Failure code [0410KA] Fuel LV. Sensor Failure.......................................................................

4 Failure code [0410KB] Fuel LV. Sensor Failure.......................................................................

6 Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of VHMS-LED display from n5 to 51) .............................................................

8 Failure code [8800ZG] Auto grease abnormally......................................................................

9 Failure code [7@HAZL] VR1/P1F Relief Press Abnormality ................................................... 10 Failure code [7@HBZL] VL1/P1R Relief Press Abnormality ................................................... 11 Failure code [7@HCZL] VR2/P2F Relief Press Abnormality................................................... 12 Failure code [7@HDZL] VL2/P2R Relief Press Abnormality ................................................... 14 Failure code [AA10NX] Aircleaner Clogging............................................................................ 16 Failure code [AB00KE] Charge Voltage Low ........................................................................... 18 Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of VHMS-LED display from n9 to 11) ............................................................. 20 Failure code [B@BAZG] Eng. Oil Press. Low ......................................................................... 22 Failure code [B@BAZK] Eng. Oil Level Low ........................................................................... 24 Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 26 Failure code [B@BCZK] Eng. Water Lvl Low .......................................................................... 28 Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61) ............................................................. 30 Failure code [B@HANS] Hydr. Oil Overheat ........................................................................... 32 Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMS-LED display from n5 to 52) ............................................................. 34 Failure code [CA111] ECM Critical Internal Failure ................................................................. 36 Failure code [CB111] ECM Critical Internal Failure ................................................................. 38 Failure code [CA115] Eng. Ne and Bkup Speed Sens Error ................................................... 40 Failure code [CB115] Eng. Ne and Bkup Speed Sens Error ................................................... 41 Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 42 Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 44 Failure code [CA131] Throttle Sensor High Error .................................................................... 46

PC2000-8

7

SEN01609-08

00 Index and foreword

Failure code [CA132] Throttle Sensor Low Error..................................................................... 48 Failure code [CA135] Eng Oil Press Sensor High Error .......................................................... 50 Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................... 52 Failure code [CA144] Coolant Temp Sens High Error ............................................................. 54 Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 56 Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 58 Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 60 Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 62 Failure code [CB187] Sens Supply 2 Volt Low Error ............................................................... 62 Failure code [CA212] Eng Oil Temp Sensor High Error........................................................... 64 Failure code [CA213] Eng Oil Temp Sensor Low Error ........................................................... 66 Troubleshooting by failure code, Part 2 SEN02097-00 Troubleshooting by failure code, Part 2.......................................................................................

4 Failure code [CA221] Ambient Press Sens High Error ............................................................

4 Failure code [CA222] Ambient Press Sens Low Error.............................................................

6 Failure code [CA227] Sens Supply 2 Volt High Error ..............................................................

8 Failure code [CB227] Sens Supply 2 Volt High Error .............................................................. 10 Failure code [CA234] Eng Over Speed.................................................................................... 12 Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 14 Failure code [CB238] Ne Speed Sens Supply Volt Error ......................................................... 16 Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 18 Failure code [CB263] Fuel Temp Sensor High Error ............................................................... 20 Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 21 Failure code [CB265] Fuel Temp Sensor Low Error ................................................................ 21 Failure code [CA271] IMV/PCV1 Short Error........................................................................... 22 Failure code [CB271] IMV/PCV1 Short Error........................................................................... 24 Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 26 Failure code [CB272] IMV/PCV1 Open Error .......................................................................... 28 Failure code [CA273] PCV2 Short Error .................................................................................. 30 Failure code [CB273] PCV2 Short Error .................................................................................. 32 Failure code [CA274] PCV2 Open Error.................................................................................. 34 Failure code [CB274] PCV2 Open Error.................................................................................. 36 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 38 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................ 40 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................ 42 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................ 44 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................ 46 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................ 48 Failure code [CA342] Calibration Code Incompatibility ........................................................... 50 Failure code [CB342] Calibration Code Incompatibility ........................................................... 50 Failure code [CA351] Injectors Drive Circuit Error................................................................... 52 Failure code [CB351] Injectors Drive Circuit Error................................................................... 54 Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 56 Failure code [CB352] Sens Supply 1 Volt Low Error ............................................................... 56 Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 58 Failure code [CB386] Sens Supply 1 Volt High Error .............................................................. 60 Failure code [CA441] Battery Voltage Low Error ..................................................................... 62 Failure code [CB441] Battery Voltage Low Error ..................................................................... 62 Failure code [CA442] Battery Voltage High Error .................................................................... 63 Failure code [CB442] Battery Voltage High Error .................................................................... 63 Failure code [CA449] Rail Press Very High Error .................................................................... 64 Failure code [CB449] Rail Press Very High Error .................................................................... 64

8

PC2000-8

00 Index and foreword

SEN01609-08

Troubleshooting by failure code, Part 3 SEN02098-00 Troubleshooting by failure code, Part 3.......................................................................................

4 Failure code [CA451] Rail Press Sensor High Error................................................................

4 Failure code [CB451] Rail Press Sensor High Error................................................................

6 Failure code [CA452] Rail Press Sensor Low Error ................................................................

8 Failure code [CB452] Rail Press Sensor Low Error ................................................................

8 Failure code [CA553] Rail Press High Error ............................................................................

9 Failure code [CB553] Rail Press High Error ............................................................................ 10 Failure code [CA554] Rail Press Sensor In Range Error ........................................................ 11 Failure code [CB554] Rail Press Sensor In Range Error ........................................................ 11 Failure code [CA559] Rail Press Low Error............................................................................. 12 Failure code [CB559] Rail Press Low Error............................................................................. 16 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 20 Failure code [CB689] Eng Ne Speed Sensor Error ................................................................. 22 Failure code [CA691] Intake Air Temp Sens High Error .......................................................... 24 Failure code [CA692] Intake Air Temp Sens Low Error ........................................................... 26 Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 27 Failure code [CB731] Eng Bkup Speed Sens Phase Error...................................................... 27 Failure code [CA757] All Persistent Data Lost Error ............................................................... 28 Failure code [CB757] All Persistent Data Lost Error ............................................................... 28 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 30 Failure code [CB778] Eng Bkup Speed Sensor Error.............................................................. 32 Failure code [CA781] CEN Communication Error ................................................................... 34 Failure code [CB781] CEN Communication Error ................................................................... 36 Failure code [CA1117] Persistent Data Lost Error ................................................................... 37 Failure code [CB1117] Persistent Data Lost Error ................................................................... 37 Failure code [CA1257] Harness Key Error .............................................................................. 38 Failure code [CB1257] Harness Key Error .............................................................................. 39 Failure code [CB1548] Inj #7(R#1) Open/Short Error.............................................................. 40 Failure code [CB1549] Inj #8(R#2) Open/Short Error.............................................................. 42 Failure code [CB1551] Inj #10(R#4) Open/Short Error............................................................ 44 Failure code [CB1552] Inj #11(R#5) Open/Short Error ............................................................ 46 Failure code [CB1553] Inj #12(R#6) Open/Short Error............................................................ 48 Failure code [CB1622] Inj #9(R#3) Open/Short Error.............................................................. 50 Failure code [CA1633] KOMNET Data link Time out Error...................................................... 52 Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 54 Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 56 Failure code [CA2249] Rail Press Very Low Error................................................................... 57 Failure code [CB2249] Rail Press Very Low Error................................................................... 57 Failure code [CA2555] Grid Heater Relay Volt Low Error ....................................................... 58 Failure code [CA2556] Grid Heater Relay Volt High Error....................................................... 60 Troubleshooting by failure code, Part 4 SEN02099-01 Troubleshooting by failure code, Part 4.......................................................................................

4 Failure code [D110KB] Battery Relay Drive S/C......................................................................

4 Failure code [D163KB] Flash Light Relay S/C.........................................................................

6 Failure code [D195KA] Step Light Relay Disc .........................................................................

8 Failure code [D195KY] Step Light Relay S/C .......................................................................... 10 Failure code [D1E9KB] Wiper Drive Relay 1 S/C .................................................................... 12 Failure code [D1EAKB] Wiper Drive Relay 2 S/C.................................................................... 14 Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit ............................................. 16 Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit............................................. 18 Failure code [DA22KK] Pump 1 Solenoid Power Low Error.................................................... 20 Failure code [dA22KK] Pump 2 Solenoid Power Low Error .................................................... 22 Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error................................................... 24 Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error ................................................... 26 Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................ 28 Failure code [DA29KQ] Pump 1 Model Select Abnormality .................................................... 30 Failure code [dA29KQ] Pump 2 Model Select Abnormality ..................................................... 32 PC2000-8

9

SEN01609-08

00 Index and foreword

Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) ............................................... 34 Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected) ................................................ 36 Failure code [DA2TMC] Pump Comm. ECM Child Abnormality .............................................. 38 Failure code [DBB0KK] VHMS Source Voltage Error (or change of VHMS-LED display from n9 to 01) ............................................................. 40 Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nF to 11) ............................................................. 42 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-LED display from n9 to 04) ............................................................. 44 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02) ............................................................. 46 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02) ............................................................. 48 Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of VHMS-LED display from n4 to 01) ............................................................. 50 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C .............................................................. 52 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-LED display from n5 to 01) ............................................................. 54 Troubleshooting by failure code, Part 5 SEN02100-00 Troubleshooting by failure code, Part 5.......................................................................................

4 Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 12) .............................................................

4 Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 22) .............................................................

6 Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of VHMS-LED display from n3 to 11) .............................................................

8 Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of VHMS-LED display from n3 to 21) ............................................................. 10 Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 24) ............................................................. 12 Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26) ............................................................. 14 Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of VHMS-LED display from n3 to 23) ............................................................. 16 Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of VHMS-LED display from n3 to 26) ............................................................. 18 Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality ...................................... 20 Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality ...................................... 22 Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality ...................................... 24 Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality ...................................... 26 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32) ............................................................. 28 Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 31) ............................................................. 30 Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of VHMS-LED display from n5 to 53) ............................................................. 32 Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality ............................................. 34 Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality ............................................. 36 Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality ............................................ 38 Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality ............................................. 40 Failure code [DHPSKX] Auto Grease Press Sensor Abnormality ........................................... 42 Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit........................................... 44 Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit ........................................... 46 Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality........................................... 48 Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality ..................................... 50 Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality .................................... 52 Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality ................................... 54 Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality .................................... 56

10

PC2000-8

00 Index and foreword

SEN01609-08

Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality ...................................... 58 Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality...................................... 60 Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality ................................. 62 Troubleshooting by failure code, Part 6 SEN02101-00 Troubleshooting by failure code, Part 6.......................................................................................

3 Failure code [DUM3KB] Auto Grease Caution LED Short Circuit ...........................................

3 Failure code [DUM4KB] FAN Reverse LED Short Circuit........................................................

4 Failure code [DV20KB] Travel Alarm S/C................................................................................

5 Failure code [DW41KA] Swing Priority Sol Open Circuit.........................................................

7 Failure code [DW41KB] Swing Priority Sol Short Circuit .........................................................

9 Failure code [DW45KA] Swing Brake Sol. Disc....................................................................... 11 Failure code [DW45KB] Swing Brake Sol. S/C........................................................................ 14 Failure code [DW91KA] Straight-Travel Sol. Disc.................................................................... 16 Failure code [DW91KB] Straight-Travel Sol. S/C..................................................................... 18 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. ...................................................... 20 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C ........................................................ 21 Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit..................................... 22 Failure code [DW7BKB] Fan Reverse Sol. S/C....................................................................... 24 Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit....................................... 26 Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit....................................... 28 Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit ............................................... 30 Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit ............................................... 32 Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit............................................... 34 Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit............................................... 36 Failure code [DWA5KA] Auto Grease Sol Open Circuit .......................................................... 38 Failure code [DWA5KB] Auto Grease Sol Short Circuit........................................................... 40 Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit ............................................... 41 Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit................................................ 43 Failure code [DWK0KA] 2-stage Relief Sol. Disc. ................................................................... 45 Failure code [DWK0KB] 2-stage Relief Sol. S/C ..................................................................... 47 Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit ........................................ 48 Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit ........................................ 49 Troubleshooting by failure code, Part 7 SEN02102-00 Troubleshooting by failure code, Part 7.......................................................................................

3 Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit ...........................................

3 Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit ...........................................

5 Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit............................................

6 Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit ............................................

7 Failure code [DXAAKA] P1F EPC Sol Disc .............................................................................

8 Failure code [DXAAKB] P1F EPC Sol S/C .............................................................................. 10 Failure code [DXABKA] P1R Pump EPC Sol. Disc. ................................................................ 12 Failure code [DXABKB] P1R Pump EPC Sol. S/C .................................................................. 14 Failure code [DXACKA] P2F Pump EPC Sol. Disc. ................................................................ 16 Failure code [DXACKB] P2F Pump EPC Sol. S/C .................................................................. 18 Failure code [DXADKA] P2R Pump EPC Sol. Disc. ................................................................ 20 Failure code [DXADKB] P2R Pump EPC Sol. S/C .................................................................. 22 Failure code [DY2CKB] Washer Drive S/C.............................................................................. 24 Failure code [DY20MA] Low Wiper Working Abnormality ....................................................... 26 Failure code [DY2FMA] Upper Wiper Working Abnormality .................................................... 29 Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38) ............................................................. 32 Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 62) ............................................................. 34 Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 72) ............................................................. 36 Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 61) ............................................................. 38

PC2000-8

11

SEN01609-08

00 Index and foreword

Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 71) ............................................................. 40 Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 82) ............................................................. 42 Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 92) ............................................................. 44 Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of VHMS-LED display from n3 to 81) ............................................................. 46 Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of VHMS-LED display from n3 to 91) ............................................................. 48 Failure code [LA10ZL] RAD system fan pump relief pressure high error ................................ 50 Failure code [LA20ZL] O/C system pump relief pressure high error ....................................... 51 Troubleshooting of electrical system (E-mode) SEN02103-01 Troubleshooting of electrical system (E-mode) ...........................................................................

1 Before carrying out troubleshooting of electrical system .........................................................

3 Contents of troubleshooting table ............................................................................................

8 E-1 When starting switch is turned ON, machine monitor displays nothing ............................ 10 E-2 When starting switch turned ON (before starting engine), basic check item lights up ...... 12 E-3 Engine does not start (Engine does not turn).................................................................... 14 E-4 Auto-decelerator does not operate.................................................................................... 18 E-5 Automatic warm-up system does not operate................................................................... 19 E-6 Preheater does not work ................................................................................................... 20 E-7 Whole work equipment, swing operation and machine travel operation are disabled ...... 22 E-8 Machine push-up function does not work.......................................................................... 24 E-9 Boom shockless function cannot be released................................................................... 26 E-10 Machine monitor does not display some items ............................................................... 28 E-11 Contents of display by machine monitor are different from applicable machine ............. 29 E-12 Fuel level monitor lights up in red while engine is running.............................................. 30 E-13 Hydraulic oil temperature gauge does not indicate normally .......................................... 31 E-14 Fuel level gauge does not indicate normally ................................................................... 32 E-15 Swing lock monitor does not indicate normally ............................................................... 34 E-16 Machine monitor display anything even when operated on monitor switch section........ 36 E-17 Wiper does not work ....................................................................................................... 37 E-18 Monitoring function does not display "Travel" normally................................................... 44 E-19 Travel alarm does not sound........................................................................................... 46 E-20 All of room lamp, headlamp and working lamp do not light up........................................ 47 E-21 Air conditioner does not work.......................................................................................... 52 E-22 Step light does not light up or goes off ............................................................................ 54 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02104-01 Troubleshooting of hydraulic and mechanical system (H-mode).................................................

3 Before troubleshooting for hydraulic and mechanical systems................................................

3 Table of failure modes and causes ..........................................................................................

8 Information in troubleshooting table......................................................................................... 10 H-1 Speed or power of whole work equipment, travel, and swing is low ................................. 11 H-2 Engine speed lowers remarkably or engine stalls............................................................. 13 H-3 Work equipment, swing, and travel mechanism do not move........................................... 14 H-4 Abnormal noise comes from around hydraulic pump........................................................ 16 H-5 Speed or power of boom is low......................................................................................... 17 H-6 Speed or power of arm is low............................................................................................ 19 H-7 Speed or power of bucket is low ....................................................................................... 20 H-8 Boom does not move ........................................................................................................ 21 H-9 Arm does not move........................................................................................................... 21 H-10 Bucket does not move .................................................................................................... 21 H-11 Hydraulic drift of work equipment is large. ...................................................................... 22 H-12 Time lag of work equipment is large ............................................................................... 23 H-13 Heavy lift function does not work or is not reset. ............................................................ 24 H-14 Machine push-up function does not work or is not reset................................................. 24

12

PC2000-8

00 Index and foreword

SEN01609-08

H-15 Boom shockless function does not work or is not reset.................................................. 24 H-16 Machine gradually deviates during traveling................................................................... 26 H-17 Machine deviates excessively when started to travel ..................................................... 29 H-18 Machine deviates excessively during multiple operations .............................................. 30 H-19 Traveling speed or power is low ..................................................................................... 30 H-20 Travel system does not move (only one side) ................................................................ 31 H-21 Upper structure does not swing ...................................................................................... 32 H-22 Swing speed or acceleration is low................................................................................. 34 H-23 In compound operation of work equipment, swing speed or acceleration is low ............ 36 H-24 Upper structure overruns remarkably when it stops swinging ........................................ 37 H-25 Large shock is made when upper structure stops swinging ........................................... 38 H-26 Large abnormal sound comes from when upper structure stops swinging..................... 39 H-27 Hydraulic drift of work equipment is large in swing operation ......................................... 40 H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) .............. 41 H-29 Bottom dump speed or power is lower (Loading shovel specification) ........................... 42 H-30 Bottom dump cylinder does not move (Loading shovel specification) ............................ 43 Troubleshooting of mechanical system (S-mode) SEN02105-00 Troubleshooting of mechanical system (S-mode) .......................................................................

3 Method of using troubleshooting charts...................................................................................

3 S-1 Starting performance is poor .............................................................................................

6 S-2 Engine does not start ........................................................................................................

7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations ........................................................................................ 11 S-5 Engine does not rotate smoothly ...................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16 S-9 Oil becomes contaminated quickly ................................................................................... 17 S-10 Fuel consumption is excessive ....................................................................................... 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 19 S-12 Oil pressure drops........................................................................................................... 20 S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21 S-14 Coolant temperature becomes too high (overheating).................................................... 22 S-15 Abnormal noise is made ................................................................................................. 23 S-16 Vibration is excessive ..................................................................................................... 24 50 Disassembly and assembly General information on disassembly and assembly SEN02133-01 General information on disassembly and assembly....................................................................

2 How to read this manual..........................................................................................................

2 Coating materials list ...............................................................................................................

4 Special tool list.........................................................................................................................

7 Sketches of special tools ......................................................................................................... 10 Engine and cooling system SEN02134-02 Engine and cooling system .........................................................................................................

2 Removal and installation of power container assembly...........................................................

2 Removal and installation of engine, PTO and hydraulic pump assembly................................

7 Removal and installation of radiator assembly ........................................................................ 19 Removal and installation of aftercooler assembly ................................................................... 20 Removal and installation of hydraulic oil cooler assembly ...................................................... 22 Removal and installation of fuel cooler assembly.................................................................... 23 Removal and installation of cooling assembly ......................................................................... 24 Removal and installation of fan motor assembly ..................................................................... 28 Removal and installation of fuel tank assembly....................................................................... 29

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13

SEN01609-08

00 Index and foreword

Engine SEN02135-02 Engine .........................................................................................................................................

2 Removal and installation of fuel supply pump assembly .........................................................

2 Removal and installation of cylinder head assembly ...............................................................

5 Removal and installation of fuel injector .................................................................................. 19 Removal and installation of engine front oil seal ..................................................................... 30 Removal and installation of engine rear oil seal ...................................................................... 33 Power train SEN02136-00 Power train ..................................................................................................................................

2 Removal and installation of PTO assembly .............................................................................

2 Disassembly and assembly of PTO assembly.........................................................................

3 Removal and installation of swing motor and swing machinery assembly ..............................

7 Disassembly and assembly of swing machinery assembly .....................................................

9 Removal and installation of swing circle assembly .................................................................. 19 Removal and installation of final drive assembly ..................................................................... 20 Disassembly and assembly of final drive assembly................................................................. 22 Undercarriage and frame SEN02137-01 Undercarriage and frame ............................................................................................................

2 Removal and installation of track shoe assembly....................................................................

2 Removal and installation of idler assembly..............................................................................

4 Disassembly and assembly of idler assembly .........................................................................

5 Disassembly and assembly of idler adjust cylinder assembly .................................................

7 Removal and installation of idler cushion cylinder assembly ...................................................

8 Disassembly and assembly of idler cushion cylinder assembly ..............................................

9 Removal and installation of track roller assembly.................................................................... 10 Disassembly and assembly of track roller assembly ............................................................... 11 Removal and installation of carrier roller assembly ................................................................. 13 Disassembly and assembly of carrier roller assembly............................................................. 14 Removal and installation of revolving frame assembly ............................................................ 18 Removal and installation of counterweight assembly .............................................................. 21 Removal and installation of hydraulic ladder ........................................................................... 22 Hydraulic system SEN02138-01 Hydraulic system .........................................................................................................................

2 Removal and installation of hydraulic tank assembly ..............................................................

2 Removal and installation of hydraulic pump assembly ............................................................

5 Removal and installation of hydraulic pump input shaft oil seal .............................................. 10 Removal and installation of control valve assembly ................................................................ 11 Disassembly and assembly of control valve assembly............................................................ 18 Removal and installation of center swivel joint assembly ........................................................ 22 Disassembly and assembly of center swivel joint assembly.................................................... 23 Removal and installation of swing motor assembly ................................................................. 24 Removal and installation of travel motor assembly ................................................................. 25 Disassembly and assembly of work equipment PPC valve assembly..................................... 26 Disassembly and assembly of travel PPC valve assembly ..................................................... 28 Disassembly and assembly of hydraulic cylinder assembly (Backhoe specification) .............. 29 Disassembly and assembly of hydraulic cylinder assembly (Loading shovel specification).... 36 Work equipment SEN02139-01 Work equipment ..........................................................................................................................

2 Removal and installation of bucket cylinder assembly (Backhoe specification) ......................

2 Removal and installation of bucket cylinder assembly (Loading shovel specification) ............

4 Removal and installation of bucket assembly (Backhoe specification)....................................

6 Removal and installation of bucket assembly (Loading shovel specification) .........................

8 Removal and installation of arm cylinder (Backhoe specification)........................................... 10 Removal and installation of arm cylinder (Loading shovel specification)................................. 12 Removal and installation of arm assembly (Backhoe specification) ........................................ 13 Removal and installation of arm assembly (Loading shovel specification) .............................. 15 Removal and installation of boom cylinder assembly (Backhoe specification) ........................ 16

14

PC2000-8

00 Index and foreword

SEN01609-08

Removal and installation of boom cylinder assembly (Loading shovel specification).............. 18 Removal and installation of boom assembly (Backhoe specification) ..................................... 20 Removal and installation of boom assembly (Loading shovel specification) ........................... 22 Removal and installation of bottom dump cylinder assembly (Loading shovel specification).. 24 Cab and its attachments SEN02140-01 Cab and its attachments..............................................................................................................

2 Removal and installation of operator cab assembly ................................................................

2 Removal and installation of operator cab glass (adhesion glass) ...........................................

5 Removal and installation of operator cab (assembly-type)...................................................... 12 Removal and installation of cab base assembly...................................................................... 13 Electrical system SEN02141-01 Electrical system .........................................................................................................................

2 Removal and installation of air conditioner unit assembly .......................................................

2 Removal and installation of monitor assembly ........................................................................

6 Removal and installation of engine controller assembly..........................................................

7 Removal and installation of pump controller assembly ...........................................................

8 Removal and installation of VHMS controller assembly ..........................................................

9 Removal and installation of Orbcomm terminal assembly for VHMS ......................................

9 90 Diagrams and drawings Hydraulic diagrams and drawings SEN01629-00 Hydraulic diagrams and drawings ...............................................................................................

3 Hydraulic circuit diagram .........................................................................................................

3 Electrical diagrams and drawings SEN01630-04 Electrical circuit diagram (1/12) ...............................................................................................

3 Electrical circuit diagram (2/12) ...............................................................................................

5 Electrical circuit diagram (3/12) ...............................................................................................

7 Electrical circuit diagram (4/12) ...............................................................................................

9 Electrical circuit diagram (5/12) ............................................................................................... 11 Electrical circuit diagram (6/12) ............................................................................................... 13 Electrical circuit diagram (7/12) ............................................................................................... 15 Electrical circuit diagram (8/12) ............................................................................................... 17 Electrical circuit diagram (9/12) ............................................................................................... 19 Electrical circuit diagram (10/12) ............................................................................................. 21 Electrical circuit diagram (11/12) ............................................................................................. 23 Electrical circuit diagram (12/12) ............................................................................................. 25 Connector arrangement diagram............................................................................................. 27

PC2000-8

15

SEN02134-02

Engine and cooling system

50 Disassembly and assembly

1

4.

Remove clamp and drain coolant from the hose (1).

6

Removal and installation of power 1 container assembly

Coolant: 180 l

Removal

k Lower

the work equipment completely to the ground and stop the engine. k Loosen the oil filler cap gradually to release the internal pressure of the hydraulic tank k Set the work equipment lock lever to the lock position. k Disconnect the cable from the negative (–) terminal of the battery. k In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then disconnect the heater hose. k Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.

1.

Collect the air conditioner refrigerant (R134a) from air conditioner circuit. [*1]

2.

Remove counterweight assembly, referring to "Removal and installation of counterweight assembly".

3.

Close fuel tank valve.

2

5.

Drain hydraulic oil.

6

Hydraulic tank: 1,300 l

6.

Disconnect hoses (2) to (6). a Prepare a container and oil plug to catch oil leaks.

7.

Disconnect suction hoses (7) to (9). a MIKALOR clamp. [*2] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.)

PC2000-8

50 Disassembly and assembly

SEN02134-02

11. Lift and remove tail pipes (14).

8.

Disconnect fuel hoses (10).

9.

Disconnect heater hoses (11). [*3] a Disconnect 4 air conditioner hoses AH inside the container. (Refer to next item)

12. Remove cover A (15).

13. Remove bracket (16).

14. Disconnect 4 oil hoses (17) and 2 oil hoses (18).

15. Remove cover (19).

10. Disconnect clips (12) and 4 air conditioner hoses (13) inside the power container. [*4] a The air conditioner hoses (13) are composed of 2 stages. a Be careful for the air conditioner circuit hoses so that dirt, water may not enter. a The heater hoses HS and fuel hoses FH have been disconnected in the previous step.

PC2000-8

16. Disconnect connectors (20).

17. Disconnect clamp (21). a HSTT: Hydraulic tank

3

SEN02134-02

18. Open battery cover (22) from the bottom of the ladder R located behind the operator cab.

50 Disassembly and assembly a

Harnesses (27) and (28) have been pulled out.

19. Disconnect 2 negative terminals (23) and 2 positive terminals (24).

22. Disconnect fuel hose (29) from the bottom rear of the power container.

20. Disconnect connectors (25) and (26) from the rear of the battery.

23. Disconnect hose clamps (30).

21. Pull out harnesses (27) and (28).

4

PC2000-8

50 Disassembly and assembly

SEN02134-02

24. Lift and remove deck assembly (31).

4

Deck assembly: Approx. 260 kg

27. Lift and remove power container assembly (35).

25. Lift and remove deck assembly (32).

4

Deck assembly: Approx. 260 kg

4

Power container assembly: Approx. 16,300 kg

26. Remove power container M30 mounting bolts (33); 5 bolts each from 4 places. [*5] a The plate (34) can be removed from backside.

PC2000-8

5

SEN02134-02

50 Disassembly and assembly

Installation

When the current hose is reused Align the clamp position to the trace of the clamp left on the hose.

3 Clamping bolt: Min. 6 Nm {0.6 kgm}

q

Carry out the installation in the reverse order of removal. [*1], [*4] a When installing the hoses of the air conditioner circuit, take care that dirt, dust, water, etc. will not enter them. a When installing each air conditioner hose, check that O-ring (70) is fitted to it. a Check O-ring (70) for a flaw and deterioration. a When connecting each refrigerant pipe, apply compressor oil for new refrigerant (R134a) (DENSO: ND-OIL8 or ZEXEL ZXL100PT (equivalent to PAGE46) to O-ring (70)).

2 Apply engine oil (EO15W-40) to threaded part and seat of mounting bolt.

3 Hose clamp: 8.83 – 14.7 Nm {0.9 – 1.5 kgm} 3 Threaded part of hose (M16 × 1.5): 12 – 15 Nm {1.2 – 1.5 kgm} 3 Threaded part of hose (M22 × 1.5): 20 – 25 Nm {2.0 – 2.5 kgm} 3 Threaded part of hose (M24 × 1.5): 30 – 35 Nm {3.0 – 3.5 kgm}

q

q

When a new hose is used Tighten the bolt until (BDG) dimension meets the following.

Hoses (7) and (9): 12 – 15 mm Hose (8): 17 – 20 mm

[*3]

3 Heater hose clamp:

5.9 ± 0.49 Nm {0.6 ± 0.05 kgm} [*5]

3 Power container mounting bolt:

3,430 – 4,212 Nm {350 – 430 kgm} q

Refilling with oil (Hydraulic tank) Fill oil up to the specified level from the oil filler port, start the engine to circulate oil in the pipe and then confirm the oil level again.

5

[*2] Suction hose clamp a Use new MIKALOR clamp.

2 Entire perimeter of hose on the tube side: Adhesive (ThreeBond No.4314) a Apply the adhesive uniformly along the entire perimeter 1) Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) 2) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm 3) Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench. a Displace the tightening positions of the adjacent clamps by 180°.

6

q

Hydraulic tank (Hydraulic tank refill oil capacity): Approx. 1,300 l

Refilling with coolant Fill coolant up to the specified level from the coolant filler, start the engine to circulate the coolant and then confirm the coolant level again.

5

Coolant: 180 l

q

Filling of refrigerant Fill the air conditioner circuit with the refrigerant (R134a). a Filling amount: 950 ± 50 g (per unit of air conditioner compressor) a Two air compressors are used.

q

Bleed air from the main pump, referring to "Bleeding air from each part" in Testing and adjusting.

PC2000-8

50 Disassembly and assembly

SEN02134-02

Removal and installation of engine, PTO and hydraulic pump 1 assembly Removal 1.

Remove power container assembly, referring to "Removal and installation of power container assembly."

2.

Remove air cleaner upper cover (1).

3.

Remove clamps (2), and then pull out 2 tubes (3). [*1] 9.

4.

Remove hand rails (4).

5.

Remove rear covers (5) and (6). a SWB: Emergency engine stop switch – behind

Disconnect connector A08 (12) and ground TM1 (13) from the inside of emergency engine stop switch – behind (SWB).

10. Disconnect connector L05B (14) from the bottom of SWB. 11. Disconnect connector L08B (15).

12. Remove clip and disconnect harnesses (16).

6.

Disconnect connector A07 (140) from the backside of emergency engine stop switch – front (SWF).

7.

Remove front covers (7) and (8).

8.

Remove upper covers (9) to (11). a SWF: Emergency engine stop switch – front

PC2000-8

7

SEN02134-02

13. Disconnect connector S27B (150) from backside of DSB (door switch - behind).

50 Disassembly and assembly a

In the case of low-grade fuel specification, disconnect connector (141) from priming pump timer (PPT) between brackets (24) and (25).

14. Remove clips (17) and disconnect muffler drain tubes (18).

15. Remove clips (19) and disconnect muffler drain hoses (20).

16. Disconnect heater hoses (21) and (22).

20. Disconnect 4 connectors (151) from the bottom. P41A, P41B, P41C and P41D from the top.

17. Disconnect 2 hoses (23).

21. Disconnect 4 connectors (152). P41A, P41B, P41C and P41D from the top.

18. Disconnect brackets (24) and (25).

22. Remove clip and disconnect harness (153).

19. Remove clip and disconnect harnesses (26).

8

PC2000-8

50 Disassembly and assembly

23. Disconnect connectors L08A (154) and S27A (155).

SEN02134-02

30. Disconnect connector L13 (157) from the front of machine in the pump room.

24. Remove clip and disconnect harness (156).

31. Disconnect 2 air cleaner hoses (33).

[*2]

25. Disconnect connector P24 (27).

26. Disconnect clips (28).

32. Lift and remove hood assembly (34).

4

Hood assembly: 210 kg

27. Disconnect fan connector V18 (29).

28. Disconnect connectors M34 (30) and M35 (31) from the compressor.

29. Disconnect harness (32).

PC2000-8

9

SEN02134-02

33. Remove cover (35).

50 Disassembly and assembly a

In the case of low-grade fuel specification, disconnect fuel filter assembly (145).

34. Lift and remove muffler and bracket assembly (36).

36. Remove bracket (38). a Remove the opposite side at the same procedures.

37. Temporarily lift air inlet duct assembly (39), and lift and remove it.

4

Air inlet duct assembly: 450 kg

35. Remove dividing boards A, B and C (37) between the engine room and pump room.

38. Remove 2 clamps (40).

39. Disconnect 2 tubes (41).

40. Remove clamp (42).

41. Disconnect tube (43).

42. Disconnect hose (44).

10

PC2000-8

50 Disassembly and assembly

SEN02134-02

43. Loosen clamps for hoses (45) to (47). [*3] a Apply a marking to the hose end and tube so that their original insertion positions may be identified in later reference. (See the following figure.)

48. Disconnect 3 radiator lower hoses (51).

[*5]

44. Remove dividing board (D) between the radiator room and engine room.

45. Remove clamp bracket (48).

46. Disconnect 2 tube clamps (49).

[*4]

47. Remove 2 tubes (50). a Remove the opposite side at the same procedures.

49. Remove cover (52).

50. Disconnect 2 radiator upper hoses (53).

[*6]

51. Disconnect hose (54).

52. Temporarily lift cooling (radiator, aftercooler and fan) assembly (55), and lift and remove it. a Holes are provided on the top of the frame for lifting.

4

PC2000-8

Cooling (radiator, aftercooler and fan) assembly: Approx. 1,200 kg

11

SEN02134-02

53. Disconnect 2 tube clamps (56).

50 Disassembly and assembly a 60. and 61. are low-grade fuel specification only 60. Disconnect fuel hoses (142) and (143).

61. Remove water separator assembly (144).

54. Disconnect 3 hoses (57).

55. Disconnect tube clamp (58).

62. Disconnect hoses (64), (65) and (66).

56. Disconnect hose clamp (59).

57. Disconnect hose (60).

63. Disconnect 4 hoses (67).

64. Disconnect hose clamp (68).

65. Disconnect 2 hoses (69) and 2 hoses (70) from the fuel pre-filter.

66. Disconnect rear cover (71).

58. Disconnect 3 hoses (61) and 3 hoses (62) from the filter.

59. Disconnect rear cover (63).

67. Disconnect frame (72) in which rear covers (63) and (71) were attached, from the frame assembly (73).

12

PC2000-8

50 Disassembly and assembly

SEN02134-02

68. Remove bracket (74).

69. Remove mounting bolt, and then lift and remove frame assembly (73).

4

Frame assembly: 270 kg

76. Disconnect fuel hoses (79), (80) and (81) from the rear of the container.

77. Remove brackets (82) and (83).

78. Disconnect engine ground (84).

79. Disconnect radiator pipe (85). q Standard specification

70. Remove bracket (75).

71. Disconnect hose clamps (76). a Do not disconnect air conditioner hoses (AH).

q

Low-grade fuel specification

72. Loosen adjustment nut (170) of the air conditioner compressor.

73. Remove covers (77).

74. Remove air conditioner compressor belts (78). [*7] 75. Remove 2 air conditioner compressors (171).

PC2000-8

13

SEN02134-02

80. Disconnect fuel hose (86). q Standard specification

50 Disassembly and assembly

85. Disconnect connectors V12 (91) and V11 (93) from inside the No.1 main pump.

86. Disconnect harness (94).

q

Low-grade fuel specification 87. Disconnect connectors V15 (161) and V16 (162) from the fan pump (middle lower).

81. Disconnect hose (87) from the No.1 main pump.

82. Disconnect 2 hoses (88).

83. Disconnect hose clamp (89).

88. Disconnect connector P35 (163) from the fan pump (middle lower).

84. Disconnect hose (90).

14

PC2000-8

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50 Disassembly and assembly

SEN02134-02

89. Disconnect suction tube (95) from the No.1 main pump.

96. Disconnect connectors V14 (110) and V13 (111) from the No. 2 main pump.

90. Disconnect 3 hoses (96), (97) and (98) from the fan pump (middle lower).

97. Disconnect harnesses (112) and (113).

98. Disconnect 2 hoses (114).

99. Disconnect 2 hoses (115). a Clamps are attached to the hoses.

91. Disconnect hose P34 (100) from the fan pump (middle lower).

92. Disconnect harness (101).

100.Remove engine controller cover (116).

93. Disconnect hoses (102) to (105).

94. Disconnect fan motor connector V17 (106).

95. Disconnect hoses (107) to (109).

PC2000-8

101.Disconnect connectors CE05 (117) and CE08 (118) from the engine controller. [*8] a Remove the opposite side at the same procedures.

15

SEN02134-02

50 Disassembly and assembly

102.Remove cover (119).

110. Disconnect clips (130).

103.Disconnect connectors (120). VH16, VH17, VH18 and VH19 from the left.

111. Disconnect 2 harnesses (131) from the starting motor.

104.Disconnect terminal (121).

112. Disconnect harness (132) from the starting motor.

105. Remove clips and disconnect 2 harnesses (122).

106.Disconnect connectors PIM (123) and TIM (124).

107.Disconnect connectors (125) and E01 (126).

108.Disconnect connector CNRP (127).

109.Remove clips and disconnect 2 harnesses (128) and (129).

113. Disconnect connector P19 (133) from the PTO oil pan.

114. Disconnect clips (134) from the bottom of PTO.

16

PC2000-8

50 Disassembly and assembly

115. Temporarily lift engine, PTO and pump assembly.

Rear side fulcrum (right and left of PTO upper area): RP Front side fulcrum: FP

SEN02134-02

Installation q

Carry out the installation in the reverse order of removal.

[*1]

3 Hose clamp of Komaclone tube assembly:

5.9 ± 0.49 Nm {0.6 ± 0.05 kgm} [*2]

3 Air cleaner hose clamp:

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*3] q

a 1) 2) 116. Remove engine, PTO and pump assembly (136) mount bolts. [*9] Pump side mount bolts: (135) Radiator side mount bolt: MB

3)

117. Lift and remove engine, PTO and pump assembly (136).

4

Air hose Use new MIKALOR clamp.

Align the hose to the original position (marked position). (Air hose insertion depth: Min. 80 mm) Place the bridge (BR) under the clamping bolt and adjust the overlapping (b) between the bridge (BR) and band to 5 mm minimum. (b) dimension: Min. 5 mm Tightening of the clamp 2 Threaded portion (BC) of clamping bolt: Lubricant (PANDO 18B from ThreeBond) a Never use an impact wrench.

When the current hose is reused Align the clamp position to the trace of the clamp left on the hose.

3 Clamping bolt: Min. 6 Nm {0.6 kgm}

q

Engine, PTO and pump assembly: Approx. 6,100 kg

q

When a new hose is used Tighten the bolt until (BDG) dimension meets the following.

Dimension (BDG): 17 – 20 mm

[*4]

3 Air tube clamp: 21 Nm {2.55 kgm}

[*5]

3 Radiator hose clamp:

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*6]

3 Radiator hose clamp:

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} PC2000-8

17