Komatsu SK820-5E0 Skid-Steer Loader Shop Manual WEBM009101 PDF

Description

Komatsu SK820-5E0 Skid-Steer Loader Shop Manual WEBM009101 – PDF DOWNLOAD

FILE DETAILS:

Komatsu SK820-5E0 Skid-Steer Loader Shop Manual WEBM009101 – PDF DOWNLOAD 

Language : English
Pages : 260
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu SK820-5E0 Skid-Steer Loader Shop Manual WEBM009101 – PDF DOWNLOAD 

SERIAL NUMBER SK820-5E0 F60003 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding
for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting
and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling
each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section
explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of re manufacturing and repairing engine and replacing parts.

TABLE OF CONTENTS:

Komatsu SK820-5E0 Skid-Steer Loader Shop Manual WEBM009101 – PDF DOWNLOAD 

SERIAL NUMBER SK820-5E0 F60003 and up

Table of contents 4
Foreword, safety and general information 16
Important safety notice 16
Fire prevention 21
Dispose of waste materials 22
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Type 1 31
Type 2 32
Type 3 33
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
Table of contents 68
Specifications 69
Specification drawing 69
PC170LC-10 69
Working range drawings 70
PC170LC-10 70
Specifications 71
PC170LC-10 71
Weight table 75
Table of fuel, coolant, and lubricants 76
10 Structure and function 77
Contents 78
Engine and cooling system 79
Engine related parts 79
Specifications 80
Variable flow turbocharger 81
Specifications 83
Operation 84
EGR system piping drawing 85
Function 85
EGR system circuit diagram 87
Operation 87
EGR valve 88
Structure 88
Operation 89
EGR cooler 90
Operation 91
KCCV layout drawing 92
Operation 93
KCCV ventilator 95
Function 95
Operation 96
CDR valve 96
KDOC muffler 97
Structure 97
Function 98
Cooling system 99
Specifications 100
Power train 101
Power train system 101
Swing circle 103
Specifications 103
Swing machinery 104
Specifications 105
Final drive 106
Specifications 107
Undercarriage and frame 108
Track frame and idler cushion 108
Specifications 109
Hydraulic system 110
Hydraulic component layout 110
Valve control 113
Hydraulic tank 114
Specifications 114
Oil filler cap 115
CLSS 116
Structure of CLSS 116
Features 116
Configuration 116
Basic principle 117
Main pump 120
LS valve 128
PC valve 133
PC-EPC valve 142
Control valve 147
7-spool valve 147
8-spool valve 160
8-spool valve 163
9-spool valve 164
9-spool valve 168
Unload valve 169
Introduction of LS pressure 174
LS bypass plug 176
Pressure compensation valve 179
Boom regeneration circuit 183
Arm regeneration circuit 185
Merge-divider valve 187
LS separation valve 189
Travel junction valve 191
Boom hydraulic drift prevention valve 193
Main relief valve 196
Back pressure check valve 198
Oil cooler bypass valve 199
2-stage suction-safety valve 200
Swing motor 202
Travel motor 204
Specifications 206
Operation of travel motor 207
Parking brake operation 209
Brake valve 211
PPC valve 219
Work equipment and swing PPC valve 219
Travel PPC valve 226
1st-line attachment PPC valve (with EPC valve) 232
EPC valve 235
2-piece boom PPC valve 240
Solenoid valve 242
Attachment circuit selector valve (for high pressure circuit) 245
Function 245
Operation 245
Attachment circuit selector valve (for low pressure circuit) 247
Center swivel joint 250
Accumulator 252
PPC accumulator 252
Work equipment 253
Work equipment 253
Work equipment shim 254
Bucket play adjustment shim 255
Cab and its attachments 256
Cab mount and cab tipping stopper 256
Structure 256
ROPS cab 257
Electrical system 258
Electrical control system 258
General system drawing 258
Engine control function 260
Engine and pump combined control function 262
Control method in each mode 264
Pump and valve control function 268
2-stage relief function 270
One-touch power maximizing function 270
Auto-deceleration function 272
Engine automatic warm-up function 274
Overheat prevention function 276
Turbocharger protection function 277
Swing control function 278
Travel control function 281
PPC lock function 284
System operating lamp function 285
Oil flow adjuster function for attachment 286
System component parts 288
Pump controller 293
Input and output signals of pump controller 294
Fuel control dial 297
Resister for PC-EPC valve 298
CAN terminating resistor 299
Engine oil pressure switch 299
PPC oil pressure switch 300
Machine monitor system 301
Machine monitor 303
KOMTRAX system 322
KOMTRAX terminal 323
Sensor 325
Ambient pressure sensor 325
Charge (boost) pressure and temperature sensor 326
Coolant temperature sensor 327
Ne (crankshaft) speed sensor 327
Bkup (camshaft) speed sensor 328
Common rail pressure sensor 328
Exhaust manifold pressure sensor 329
EGR orifice temperature sensor 329
Variable flow turbocharger motor (with built-in position sensor) 330
EGR valve (with built-in position sensor) 331
Mass air flow and temperature sensor 332
Crankcase pressure sensor 332
Engine oil level sensor 333
Fuel level sensor 334
Coolant level sensor 335
Hydraulic oil temperature sensor 336
Front pump oil pressure sensor 336
Rear pump oil pressure sensor 337
PPC oil pressure sensor 338
Air cleaner clogging sensor 339
Pump swash plate sensor 339
Water-in-fuel sensor 340
20 Standard value tables 341
Contents 342
Standard service value table 343
Standard value table for engine 343
Standard value table for machine 345
Engine speed 345
Control valve spool stroke 345
Travel of control lever 346
Operating effort of control lever and pedal 346
Hydraulic pressure 347
Swing 350
Traveling 351
Work equipment 352
Performance of combined operation 355
Pump swash plate sensor 355
Characteristics of PC flow control 356
Hydraulic pump 356
Machine posture and procedure for measuring performance 357
Standard value table for electrical system 362
Controller 362
Engine control 363
Machine control 366
Machine monitor 368
30 Testing and adjusting 369
Contents 370
Related information on testing and adjusting 371
Tools for testing and adjusting 371
Sketch of tools for testing and adjusting 374
Q2: Sensor adapter 374
-: Socket 374
Engine and cooling system 375
Testing engine speed 375
Testing 375
Testing boost pressure 376
Testing 376
How to fully open engine hood 377
Testing exhaust gas color 378
Testing 378
Testing and adjusting valve clearance 379
Adjusting 380
Testing compression pressure 382
Testing 382
Testing blowby pressure 386
Testing 386
Testing engine oil pressure 387
Testing 387
Testing fuel pressure 388
Testing 390
Testing fuel discharge, return and leakage 393
Testing 394
Bleeding air from fuel system 398
Bleeding air 398
Testing fuel circuit for leakage 400
Testing 400
Handling cylinder cutout mode operation 401
Handling no-injection cranking operation 402
Checking and adjusting air conditioner compressor belt tension 403
Testing 403
Replacing fan belt 404
Replace 404
Power train 405
Testing swing circle bearing clearance 405
Testing 405
Undercarriage and frame 406
Testing and adjusting track tension 406
Testing 406
Hydraulic system 407
Releasing remaining pressure from hydraulic circuit 407
Releasing remaining pressure 407
Testing oil pressure of control circuit 408
Testing 408
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 409
Testing 409
Adjusting 411
Testing and adjusting oil pressure in pump PC control circuit 413
Testing 413
Adjusting 414
Testing and adjusting oil pressure in pump LS control circuit 416
Testing 416
Adjusting 419
Testing outlet pressure of solenoid valve 420
Testing 420
Operating condition 421
Testing PPC valve outlet pressure 423
Testing 423
Adjusting play of work equipment and swing PPC valves 425
Adjusting 425
Testing pump swash plate sensor 426
Testing 426
Isolating the parts causing hydraulic drift in work equipment 427
Testing 427
Testing and adjusting travel deviation 429
Testing 429
Adjusting 429
Testing oil leakage 431
Testing 431
Bleeding air from hydraulic circuit 434
Bleeding air 434
Cab and its attachments 436
Checking cab tipping stopper 436
Testing 436
Adjusting mirrors 437
Electrical system 439
Special functions of machine monitor 439
Ordinary functions and special functions of machine monitor 441
KOMTRAX terminal start-up procedure 497
Adjusting rearview camera angle 500
Adjusting 500
Handling voltage circuit of engine controller 502
Handling battery disconnect switch 503
Testing diodes 504
Testing 504
Pm Clinic 505
Pm Clinic service 505
Check sheet 507
40 Troubleshooting 515
Table of contents 516
Related information on troubleshooting 522
Troubleshooting points 522
Sequence of events in troubleshooting 524
Checks before troubleshooting 526
Inspection procedure before troubleshooting 528
Walk-around check 528
Testing in accordance with testing procedure 529
Preparation work for troubleshooting of electrical system 546
Preparation 546
Classification and procedure for troubleshooting 551
Procedure for troubleshooting 551
Symptom and troubleshooting numbers 554
Information in troubleshooting table 557
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 559
Connector list and layout 562
Layout of connectors (1/6) 568
Layout of connectors (2/6) 569
Layout of connectors (3/6) 570
Layout of connectors (4/6) 571
Layout of connectors (5/6) 572
Layout of connectors (6/6) 573
Connector contact identification 574
T-branch box and T-branch adapter table 612
Fuse location table 617
Connection table of fuse box 617
Locations of fusible links 618
Locations of fuse boxes and fuse No 618
Failure codes table 619
Troubleshooting by failure code (Display of code) 626
Failure code [879AKA] A/C Inner Sensor Open Circuit 626
Failure code [879AKB] A/C Inner Sensor Short Circuit 627
Failure code [879BKA] A/C Outer Sensor Open Circuit 628
Failure code [879BKB] A/C Outer Sensor Short Circuit 629
Failure code [879CKA] Ventilating Sensor Open Circuit 630
Failure code [879CKB] Ventilating Sensor Short Circuit) 631
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit 632
Failure code [879EMC] Ventilation Damper Abnormality 633
Failure code [879FMC] Air Mix Damper Abnormality 634
Failure code [879GKX] Refrigerant Abnormality 635
Failure code [989L00] Engine Controller Lock Caution 1 636
Failure code [989M00] Engine Controller Lock Caution 2 637
Failure code [989N00] Engine Controller Lock Caution 3 638
Failure code [AA10NX] Air Cleaner Clogging 639
Failure code [AB00KE] Charge Voltage Low 641
Failure code [B@BAZG] Eng Oil Press Low 643
Failure code [B@BAZK] Eng Oil Level Low 644
Failure code [B@BCNS] Eng Water Overheat 645
Failure code [B@BCZK] Eng Water Level Low 646
Failure code [B@HANS] Hyd Oil Overheat 648
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 649
Failure code [CA122] Chg Air Press Sensor High Error 650
Failure code [CA123] Chg Air Press Sensor Low Error 652
Failure code [CA131] Throttle Sensor High Error 654
Failure code [CA132] Throttle Sensor Low Error 656
Failure code [CA144] Coolant Temp Sens High Error 658
Failure code [CA145] Coolant Temp Sens Low Error 660
Failure code [CA153] Chg Air Temp Sensor High Error 662
Failure code [CA154] Chg Air Temp Sensor Low Error 664
Failure code [CA187] Sensor 2 Supply Volt Low Error 666
Failure code [CA221] Ambient Press Sensor High Error 668
Failure code [CA222] Ambient Press Sens Low Error 670
Failure code [CA227] Sensor 2 Supply Volt High Error 672
Failure code [CA234] Eng Overspeed 673
Failure code [CA238] Ne Speed Sensor Supply Volt Error 674
Failure code [CA239] Ne Speed Sens Supply Volt High Error 675
Failure code [CA271] IMV/PCV1 Short Error 676
Failure code [CA272] IMV/PCV1 Open Error 678
Failure code [CA295] Ambient Press Sens In Range Error 680
Failure code [CA322] Inj #1(L#1) Open/Short Error 681
Failure code [CA324] Inj #3(L#3) Open/Short Error 683
Failure code [CA331] Inj #2(L#2) Open/Short Error 685
Failure code [CA332] Inj #4(L#4) Open/Short Error 687
Failure code [CA343] ECM Critical Internal Failure 689
Failure code [CA351] Injectors Drive Circuit Error 690
Failure code [CA352] Sensor 1 Supply Volt Low Error 691
Circuit diagram related to sensor power supply 1 (5 V) 692
Failure code [CA356] Mass Air Flow Sensor High Error 693
Failure code [CA357] Mass Air Flow Sensor Low Error 695
Failure code [CA386] Sensor 1 Supply Volt High Error 697
Failure code [CA428] Water in Fuel Sensor High Error 698
Failure code [CA429] Water in Fuel Sensor Low Error 700
Failure code [CA435] Eng Oil Press Sw Error 702
Failure code [CA441] Battery Voltage Low Error 703
Failure code [CA442] Battery Voltage High Error 705
Failure code [CA449] Rail Press Very High Error 706
Failure code [CA451] Rail Press Sensor High Error 707
Failure code [CA452] Rail Press Sensor Low Error 709
Failure code [CA466] KVGT Motor Driver Position Error 711
Failure code [CA488] Chg Air Temp High Torque Derate 713
Failure code [CA515] Rail Press Sens Sup Volt High Error 714
Failure code [CA516] Rail Press Sens Sup Volt Low Error 716
Failure code [CA553] Rail Press High Error 718
Failure code [CA555] Crankcase Press High Error 1 719
Failure code [CA556] Crankcase Press High Error 2 720
Failure code [CA559] Rail Press Low Error 721
Check sheet for fuel pressure low error 722
Failure code [CA689] Eng Ne Speed Sensor Error 724
Failure code [CA691] Intake Air Temp Sens High Error 726
Failure code [CA692] Intake Air Temp Sens Low Error 728
Failure code [CA697] ECM Internal Temp Sensor High Error 730
Failure code [CA698] ECM Int Temp Sensor Low Error 731
Failure code [CA731] Eng Bkup Speed Sens Phase Error 732
Failure code [CA778] Eng Bkup Speed Sensor Error 733
CA778 (107 series engine) 736
Failure code [CA1117] Persistent Data Lost Error 737
Failure code [CA1695] Sensor 5 Supply Volt High Error 738
Failure code [CA1696] Sensor 5 Supply Volt Low Error 739
Circuit diagram related to sensor power supply 5 circuit 739
Failure code [CA1843] Crankcase Press Sens High Error 740
Failure code [CA1844] Crankcase Press Sens Low Error 742
Failure code [CA1896] EGR Valve Stuck Error 744
Failure code [CA1942] Crankcase Press Sens In Range Error 745
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 746
Failure code [CA2185] Throt Sensor Sup Volt High Error 747
Failure code [CA2186] Throt Sensor Sup Volt Low Error 749
Failure code [CA2249] Rail Press Very Low Error 751
Failure code [CA2272] EGR Valve Pos Sens Low Error 752
Failure code [CA2311] IMV Solenoid Error 754
Failure code [CA2349] EGR Valve Solenoid Open Error 755
Failure code [CA2353] EGR Valve Solenoid Short Error 757
Failure code [CA2357] EGR Valve Servo Error 759
Failure code [CA2373] Exhaust Manifold Press Sens High Error 760
Failure code [CA2374] Exhaust Manifold Press Sens Low Error 762
Failure code [CA2375] EGR Orifice Temp Sens High Error 764
Failure code [CA2376] EGR Orifice Temp Sens Low Error 766
Failure code [CA2554] Exh Manifold Press Sens In Range Error 768
Failure code [CA2555] Grid Htr Relay Volt Low Error 769
Failure code [CA2556] Grid Htr Relay Volt High Error 771
Failure code [CA2961] EGR Orifice Temp High Error 1 773
Failure code [CA2973] Chg Air Press Sensor In Range Error 774
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 775
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 777
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 779
Failure code [CA3741] Rail Press Valve Trip Error 781
Failure code [CA3918] KVGT Stuck Error 782
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 783
Failure code [CA3921] KVGT Servo Error 2 784
Failure code [CA3922] KVGT Motor Driver Open Error 785
Failure code [CA3923] KVGT Motor Driver Short Error 787
Failure code [D110KB] Battery Relay Drive Short Circuit 789
Failure code [D19JKZ] Personal Code Relay Abnormality 791
Failure code [D811MC] KOMTRAX Error 794
Failure code [D862KA] GPS Antenna Open Circuit 795
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) 796
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) 798
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 799
Failure code [DA20MC] Pump Controller Malfunction 801
Failure code [DA22KK] Pump Solenoid Power Low Error 802
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 804
Failure code [DA29KQ] Model Selection Abnormality 807
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) 809
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) 811
Failure code [DA2QKR] CAN2 Discon (Pump Con) 812
Failure code [DA2RKR] CAN1 Discon (Pump Con) 814
Failure code [DAF0MB] Monitor ROM Abnormality 815
Failure code [DAF0MC] Monitor Error 816
Failure code [DAF8KB] Camera Power Supply Short Circuit 817
Failure code [DAF9KQ] Model Selection Abnormality 819
Failure code [DAFGMC] GPS Module Error 820
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 821
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) 823
Failure code [DAFQKR] CAN2 Discon (Monitor) 824
Failure code [DAZ9KQ] A/C Model Selection Abnormality 825
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 826
Failure code [DB2QKR] CAN2 Discon (Engine Con) 830
Failure code [DB2RKR] CAN1 Discon (Engine Con) 834
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 838
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit 840
Failure code [DHPAMA] F Pump Press Sensor Abnormality 842
Failure code [DHPBMA] R Pump Press Sensor Abnormality 844
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 846
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 848
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 850
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality 852
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 854
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 856
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality 858
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 860
Failure code [DKR0MA] Pump Swash Plate Sensor Abnormality 862
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 864
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 866
Failure code [DV20KB] Travel Alarm Short Circuit 867
Failure code [DW43KA] Travel Speed Sol Open Circuit 869
Failure code [DW43KB] Travel Speed Sol Short Circuit 871
Failure code [DW45KA] Swing Brake Sol Open Circuit 873
Failure code [DW45KB] Swing Brake Sol Short Circuit 876
Failure code [DW91KA] Travel Junction Sol Open Circuit 878
Failure code [DW91KB] Travel Junction Sol Short Circuit 880
Failure code [DWA2KA] Attachment Sol Open Circuit 882
Failure code [DWA2KB] Attachment Sol Short Circuit 884
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 886
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 888
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit 890
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 892
Failure code [DXA8KA] PC-EPC Sol Open Circuit 894
Failure code [DXA8KB] PC-EPC Sol Short Circuit 896
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 898
Failure code [DXE4KB] Attachment Flow EPC Short Circuit) 900
Failure code [DY20KA] Wiper Working Abnormality 901
Failure code [DY20MA] Wiper Parking Abnormality 903
Failure code [DY2CKB] Washer Drive Short Circuit 905
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 907
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 909
Troubleshooting of electrical system (E-mode) 911
E-1 Engine does not start (Engine does not crank) 911
E-2 Manual preheating system does not work 917
E-3 Automatic preheating system does not work 920
E-4 While preheating is working, preheating monitor does not light up 922
E-5 When starting switch is turned to ON position, machine monitor displays nothing 924
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 927
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow 928
E-8 Engine coolant temperature monitor lights up in red while engine is running 929
E-9 Hydraulic oil temperature monitor lights up in red while engine is running 930
E-10 Charge level monitor lights up in red while engine is running 931
E-11 Fuel level monitor lights up in red while engine is running 932
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 933
E-13 Water separator monitor lights up in red while engine is running 934
E-14 Engine coolant temperature monitor lights up in red while engine is running 935
E-15 Hydraulic oil temperature monitor lights up in red while engine is running 936
E-16 Engine oil pressure monitor lights up in red while engine is running 937
E-17 Fuel gauge display does not move from minimum or maximum 938
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 939
E-19 Engine coolant temperature gauge display does not move from minimum or maximum 940
E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) 941
E-21 Hydraulic oil temperature gauge does not move from minimum or maximum 942
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) 944
E-23 Contents of display on machine monitor is different from actual machine condition 945
E-24 Some areas of machine monitor screen are not displayed 946
E-25 Function switch does not work 947
E-26 Automatic warm-up system does not operate (in cold season) 948
E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 949
E-28 Auto-deceleration function does not operate or is not canceled while lever is operated 950
E-29 Working mode selection screen is not displayed while working mode selector switch is operated 951
E-30 Setting of engine and hydraulic pump is not changed while working mode is changed 952
E-31 Travel speed monitor does not change when travel speed switch is operated 953
E-32 Travel speed does not change while travel speed selection is changed 954
E-33 Alarm buzzer does not stop sounding 955
E-34 Service meter is not displayed, while starting switch is in OFF position 956
E-35 Service mode cannot be selected 957
E-36 Any of work equipment, swing and travel does not work 958
E-37 Any of work equipment, swing and travel cannot be locked 960
E-38 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position 962
E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position 964
E-40 One-touch power maximizing function does not operate, or indicator is not displayed on monitor 966
E-41 One-touch power maximizing function cannot be canceled 968
E-42 Alarm does not sound during travel 969
E-43 Alarm does not stop sounding while machine is stopped 970
E-44 Horn does not sound 971
E-45 Horn does not stop sounding 973
E-46 Wiper monitor does not light up, or does not go out, while wiper switch is operated 975
E-47 Wiper does not operate while wiper switch is operated 976
E-48 Window washer does not operate while window washer switch is operated 978
E-49 Boom LOWER is not displayed correctly with monitoring function 979
E-50 Arm OUT is not displayed correctly with monitoring function 980
E-51 Arm IN is not displayed correctly with monitoring function 981
E-52 Boom RAISE is not displayed correctly with monitoring function 982
E-53 Bucket CURL is not displayed correctly with monitoring function 983
E-54 Bucket DUMP is not displayed correctly with monitoring function 984
E-55 Swing is not displayed correctly with monitoring function 985
E-56 Travel is not displayed correctly with monitoring function 986
E-57 Service is not displayed correctly with monitoring function 988
E-58 Attachment hydraulic circuit cannot be changed 990
E-59 KOMTRAX system does not operate normally 991
Troubleshooting of hydraulic and mechanical system (H-mode) 992
Information described in troubleshooting table (H-mode) 992
System chart of hydraulic and mechanical systems 993
Failure mode and cause table 995
H-1 All of work equipments, swing and travel operations lack speed or power 999
H-2 Engine speed drops significantly or engine stalls 1001
H-3 All work equipment, swing and travel does not work 1002
H-4 Unusual sound is heard from around hydraulic pump 1003
H-5 Fine control performance or response is poor 1004
H-6 Boom speed or power is low 1005
H-7 Arm speed or power is low 1008
H-8 Bucket speed or power is low 1011
H-9 Work equipment does not move in single operation 1013
H-10 Hydraulic drift of boom is large 1014
H-11 Hydraulic drift of arm is large 1015
H-12 Hydraulic drift of bucket is large 1016
H-13 Time lag of work equipment is large 1017
H-14 When part of work equipment is relieved singly, other parts of work equipment move 1019
H-15 One-touch power maximizing function does not operate 1020
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1021
H-17 In combined operations of swing and boom RAISE, boom rising speed is low 1022
H-18 In combined operation of swing and travel, travel speed drops largely 1023
H-19 Machine does not travel straight 1024
H-20 Travel speed is slow 1026
H-21 Machine is hard to steer or travel power is low 1028
H-22 Travel speed does not change, or travel speed is too slow or fast 1031
H-23 One of tracks does not run 1032
H-24 Upper structure does not swing to the right or left 1034
H-25 Upper structure swing only to the right or left 1035
H-26 Swing acceleration or swing speed is low in both directions (right and left) 1036
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction 1037
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1038
H-29 Upper structure overruns excessively when it stops swinging (either right or left) 1039
H-30 Shock is large when upper structure stops swinging 1040
H-31 Large unusual noise is heard when upper structure stops swinging 1041
H-32 Swing drift on a slope is large while swing parking brake is applied 1042
H-33 Swing drift on a slope is large while swing parking brake is released 1043
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed 1044
H-35 Oil flow in attachment circuit cannot be controlled 1045
Troubleshooting of engine (S-mode) 1046
Information mentioned in troubleshooting table (S mode) 1046
S-1 Engine does not crank when starting switch is turned to START position 1047
S-2 Engine cranks but no exhaust smoke comes out 1048
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1049
S-4 Engine startability is poor 1050
S-5 Engine does not pick up smoothly 1052
S-6 Engine stops during operation 1054
S-7 Engine runs rough or is unstable 1056
S-8 Engine lacks power 1057
S-9 Exhaust smoke is black 1059
S-10 Engine oil consumption is excessive 1061
S-11 Oil becomes contaminated quickly 1062
S-12 Fuel consumption is excessive 1063
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1064
S-14 Oil pressure drops 1065
S-15 Fuel mixes into engine oil 1066
S-16 Water mixes into engine oil (milky) 1067
S-17 Coolant temperature rises too high (overheating) 1068
S-18 Unusual noise is heard 1069
S-19 Vibration is excessive 1070
S-20 Air cannot be bled from fuel circuit 1071
50 Disassembly and assembly 1073
Contents 1074
Related information on disassembly and assembly 1076
How to read this manual 1076
Coating materials list 1078
Adhesive 1078
Liquid gasket 1079
Molybdenum disulfide lubricant 1079
Seizure prevention compound 1080
Grease 1080
Primer 1081
Adhesive 1081
Caulking material 1081
Special tools list 1082
Sketches of special tools 1087
Engine and cooling system 1091
Removal and installation of supply pump assembly 1091
Removal 1091
Installation 1093
Removal and installation of injector assembly 1095
Removal 1095
Installation 1097
Removal and installation of cylinder head assembly 1101
Removal 1101
Installation 1107
Removal and installation of radiator assembly 1119
Removal 1119
Installation 1120
Removal and installation of hydraulic oil cooler assembly 1121
Removal 1121
Installation 1122
Removal and installation of aftercooler assembly 1124
Removal 1124
Installation 1124
Removal and installation of engine and main pump assembly 1126
Removal 1126
Installation 1131
Removal and installation of engine front oil seal 1133
Removal 1133
Installation 1135
Removal and installation of engine rear oil seal 1137
Removal 1137
Installation 1137
Removal and installation of fuel cooler assembly 1140
Removal 1140
Installation 1140
Removal and installation of fuel tank assembly 1142
Removal 1142
Installation 1143
Removal and installation of engine hood assembly 1144
Removal 1144
Removal and installation of KDOC assembly 1146
Removal 1146
Installation 1146
Removal and installation of KCCV assembly 1148
Removal 1148
Installation 1149
Removal and installation of air cleaner assembly 1153
Removal 1153
Installation 1154
Power train 1155
Removal and installation of travel motor and final drive assembly 1155
Removal 1155
Installation 1155
Disassembly and assembly of final drive assembly 1156
Disassembly 1156
Assembly 1158
Removal and installation of swing motor and swing machinery assembly 1165
Removal 1165
Installation 1166
Disassembly and assembly of swing machinery assembly 1167
Disassembly 1167
Assembly 1170
Removal and installation of swing circle assembly 1174
Removal 1174
Installation 1174
Undercarriage and frame 1175
Separation and connection of track shoe assembly 1175
Separation 1175
Installation 1176
Removal and installation of sprocket 1177
Removal 1177
Installation 1177
Removal and installation of idler and idler cushion assembly 1178
Removal 1178
Installation 1178
Disassembly and assembly of idler assembly 1179
Disassembly 1179
Assembly 1179
Disassembly and assembly of idler cushion assembly 1182
Disassembly 1182
Assembly 1182
Disassembly and assembly of track roller assembly 1184
Disassembly 1184
Assembly 1184
Disassembly and assembly of carrier roller assembly 1186
Disassembly 1186
Assembly 1187
Removal and installation of revolving frame assembly 1189
Removal 1189
Installation 1190
Removal and installation of counterweight assembly 1191
Removal 1191
Installation 1192
Hydraulic system 1193
Removal and installation of center swivel joint assembly 1193
Removal 1193
Installation 1195
Disassembly and assembly of center swivel joint assembly 1196
Disassembly 1196
Assembly 1196
Removal and installation of hydraulic tank assembly 1197
Removal 1197
Installation 1199
Removal and installation of main pump assembly 1201
Removal 1201
Installation 1203
Removal and installation of main pump input shaft oil seal 1204
Removal 1204
Installation 1204
Removal and installation of control valve assembly 1205
Removal 1205
Installation 1207
Disassembly and assembly of control valve assembly 1209
Assembly of control valve assembly 1210
Disassembly and assembly of work equipment PPC valve assembly 1211
Disassembly 1211
Assembly 1211
Disassembly and assembly of travel PPC valve assembly 1213
Disassembly 1213
Assembly 1213
Work equipment 1215
Removal and installation of work equipment assembly ( 1-piece boom) 1215
Removal 1215
Installation 1216
Removal and installation of work equipment assembly (2-piece boom) 1218
Removal 1218
Installation 1220
Removal and installation of 1st boom assembly 1222
Removal 1222
Installation 1224
Removal and installation of 2nd boom 1226
Removal 1226
Installation 1227
Removal and installation of arm 1228
Removal 1228
Installation 1229
Disassembly and assembly of work equipment cylinder assembly 1230
Disassembly 1230
Assembly 1231
Cab and its attachments 1236
Removal and installation of operator’s cab assembly 1236
Removal 1236
Installation 1240
Removal and installation of operator cab glass (adhered glass) 1241
Removal 1243
Installation 1244
Removal and installation of front window assembly 1251
Removal 1251
Installation 1252
Removal and installation of floor frame assembly 1257
Removal 1257
Installation 1260
Removal and installation of air conditioner unit assembly 1262
Removal 1262
Installation 1265
Removal and installation of operator’s seat 1266
Removal 1266
Installation 1267
Removal and installation of seat belt 1268
Removal 1268
Installation 1268
Removal and installation of front wiper assembly 1269
Removal 1269
Installation 1271
Electrical system 1276
Removal and installation of air conditioner compressor assembly 1276
Removal 1276
Installation 1277
Removal and installation of air conditioner condenser assembly 1278
Removal 1278
Installation 1278
Removal and installation of engine controller assembly 1280
Removal 1280
Installation 1280
Removal and installation of pump controller assembly 1282
Removal 1282
Installation 1282
Removal and installation of machine monitor assembly 1285
Removal 1285
Installation 1286
Removal and installation of pump swash plate sensor 1287
Removal 1287
Installation 1287
Removal and installation of mass air flow and temperature sensor 1288
Removal 1288
Installation 1288
Removal and installation of KOMTRAX terminal assembly 1289
Removal 1289
Installation 1289
60 Maintenance standard 1291
Contents 1292
Engine and cooling system 1293
Engine mount 1293
Cooling system 1294
Power train 1295
Swing circle 1295
Swing machinery 1296
Final drive 1297
Sprocket 1299
Undercarriage and frame 1301
Track frame and idler cushion 1301
Idler 1303
Track roller 1305
Carrier roller 1306
Track shoe 1307
Triple grouser shoe 1310
Hydraulic system 1311
Hydraulic tank 1311
Main pump 1312
PC-EPC valve 1314
Control valve 1315
Travel motor 1326
Work equipment and swing PPC valve 1329
Travel PPC valve 1332
1st-line attachment PPC valve (with EPC valve) 1335
EPC valve 1337
2-piece boom PPC valve 1338
Solenoid valve 1340
Attachment circuit selector valve (for high-pressure circuit) 1341
Attachment circuit selector valve (for low-pressure circuit) 1342
Center swivel joint 1343
Work equipment 1344
Work equipment 1344
Dimensions of arm 1349
Dimensions of bucket 1351
Boom cylinder 1353
Arm cylinder 1354
Bucket cylinder 1355
80 Appendix 1357
Table of contents 1358
Air conditioner components 1359
Precautions for refrigerant 1359
Air conditioner component 1360
Configuration and function of refrigeration cycle 1363
Outline of refrigeration cycle 1364
Air conditioner unit 1366
Function 1367
Functions of major components 1369
Servomotor 1370
Expansion valve 1371
Dual pressure switch 1373
Function 1373
Air conditioner controller 1374
Compressor 1375
Function 1375
Air conditioner condenser 1376
Function 1376
Sunlight sensor 1378
Function 1378
Outer temperature sensor (outside air temperature sensor) 1379
Function 1379
Procedure for testing and troubleshooting 1380
Circuit diagram and arrangement of connector pins 1382
System diagram 1384
Input and output signals of the air conditioner controller 1385
Function 1385
Parts and connectors layout 1387
Details 1387
Testing air leakage 1391
Check) 1391
Testing with self-diagnosis function 1394
Testing outline 1394
How to open the electrical system abnormality record screen in service mode of the machine monitor 1394
Testing vent (mode) changeover 1397
Testing 1397
Testing FRESH/RECIRC air changeover 1399
Testing 1399
Testing sunlight sensor 1400
Testing 1400
Testing (dual) pressure switch for refrigerant 1401
Testing 1401
Testing relays 1402
Testing 1402
Troubleshooting chart 1 1403
Troubleshooting chart 2 1404
Information in troubleshooting table 1407
Information in troubleshooting table 1407
Failure code list related to air conditioner 1408
Failure code [879AKA] A/C Inner Sensor Open Circuit 1409
Failure code [879AKB] A/C Inner Sensor Short Circuit 1410
Failure code [879BKA] A/C Outer sensor Open Circuit 1411
Circuit diagram related to air conditioner outside air temperature sensor 1412
Failure code [879BKB] A/C Outer sensor Short Circuit 1413
Circuit diagram related to air conditioner outside air temperature sensor 1414
Failure code [879CKA] Ventilating Sensor Open Circuit 1415
Failure code [879CKB] Ventilating Sensor Short Circuit 1416
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1417
Circuit diagram related to sunlight sensor 1418
Failure code [879EMC] Ventilation Damper Abnormality 1419
Failure code [879FMC] Air Mix Damper Abnormality 1420
Failure code [879GKX] Refrigerant Abnormality 1421
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1422
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1424
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1427
A-4 Troubleshooting for FRESH/RECIRC air changeover 1429
Troubleshooting with gauge pressure 1431
Connection of service tool 1434
Precautions for disconnecting and connecting air conditioner piping 1436
Handling of compressor oil 1438
Desiccant replacement 1440
90 Diagrams and drawings 1443
Contents 1444
Hydraulic circuit diagram 1445
Symbols in hydraulic circuit diagram 1445
Hydraulic circuit diagram (1/2) 1449
Hydraulic circuit diagram (2/2) 1451
Electric circuit diagram 1453
Symbols in electric circuit diagram 1453
Electrical circuit diagram (1/7) 1457
Electrical circuit diagram (2/7) 1459
Electrical circuit diagram (3/7) 1461
Electrical circuit diagram (4/7) 1463
Electrical circuit diagram (5/7) 1465
Electrical circuit diagram (6/7) 1467
Electrical circuit diagram (7/7) 1469

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