Komatsu Hydraulic Excavator PC210-10 PC210LC-10 Shop Manual UEN05842-01 PDF

Description

Komatsu Hydraulic Excavator PC210-10 PC210LC-10 Shop Manual UEN05842-01 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC210-10 PC210LC-10 Shop Manual UEN05842-01 – PDF DOWNLOAD

Language : English
Pages :1774
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC210-10 PC210LC-10 Shop Manual UEN05842-01 – PDF DOWNLOAD

Serial Numbers
450120 and up
K60001 and up
450120 and up
K60001 and up

General precautions

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. •
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC210-10 PC210LC-10 Shop Manual UEN05842-01 – PDF DOWNLOAD

Serial Numbers
450120 and up
K60001 and up
450120 and up
K60001 and up

00 Index and foreword 3
Index 4
Foreword, safety and general information 16
Important safety notice 16
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
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 49
Standard tightening torque table 50
List of abbreviation 54
Conversion table 59
01 Specification 65
Table of contents 66
Working range drawings 68
Specifications 69
Weight table 72
Table of fuel, coolant, and lubricants 73
10 Structure and function 75
Table of contents 76
Engine and cooling system 77
Engine related parts 77
KVGT 79
EGR system piping drawing 86
EGR system circuit diagram 88
EGR valve 90
EGR cooler 92
KCCV layout drawing 93
KCCV ventilator 95
KDPF 97
Cooling system 101
Power train 103
Power train system 103
Swing circle 105
Swing machinery 106
Final drive 108
Undercarriage and frame 110
Track frame and idler cushion 110
Hydraulic system 112
Hydraulic equipment layout drawing 112
Valve control 114
Hydraulic tank 116
CLSS 118
Main pump 123
Control valve 149
Swing motor 204
Travel motor 216
PPC valve 229
Solenoid valve 251
Attachment circuit selector valve (for low pressure circuit) 254
Center swivel joint 257
Accumulator 259
ATT EPC valve assembly 260
Return oil filter 262
Quick coupler control valve 263
Work equipment 266
Work equipment 266
Work equipment shim 267
Bucket play adjustment shim 268
Cab and its attachments 269
Cab mount and cab tipping stopper 269
ROPS cab 270
Electrical system 271
Electrical control system 271
Machine monitor system 323
KOMTRAX system 345
Sensor 348
PPC levers 369
Auto grease system 371
20 Standard value tables 383
Table of contents 384
Standard service value table 385
Standard value table for engine 385
Standard value table for machine 387
Standard value table for electrical system 400
30 Testing and adjusting 411
Table of contents 412
General information on testing and adjusting 413
Tools for testing and adjusting 413
Sketch of tools for testing and adjusting 417
Engine and cooling system 418
Testing engine speed 418
Testing boost pressure 419
Testing exhaust gas color 421
Measuring and adjusting valve clearance 423
Testing compression pressure 426
Testing blowby pressure 430
Testing engine oil pressure 431
Testing EGR valve and KVGT oil pressures 432
Measuring fuel pressure 433
Measuring fuel delivery, return and leakage 439
Bleeding air from fuel system 444
Checking fuel circuit for leakage 446
Handling cylinder cutout mode operation 447
Handling no injection cranking operation 448
Checking and adjusting air conditioner compressor belt tension 449
Replacing fan belt 451
Power train 452
Testing swing circle bearing clearance 452
Undercarriage and frame 453
Testing and adjusting track shoe tension 453
Hydraulic system 454
Releasing remaining pressure from hydraulic circuit 454
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 455
Testing oil pressure of control circuit 459
Testing and adjusting oil pressure in pump PC control circuit 462
Testing and adjusting oil pressure in pump LS control circuit 465
Testing output pressure of solenoid valve 470
Testing PPC valve output pressure 474
Adjusting play of work equipment and swing PPC valves 476
Measuring and adjusting quick coupler control valve output pressure 477
Testing pump swash plate sensor 478
Isolating the parts causing hydraulic drift in work equipment 479
Testing oil leakage 480
Bleeding air from hydraulic circuit 483
Cab and its attachments 485
Checking cab tipping stopper 485
Adjusting mirrors 486
Electrical system 488
Special functions of machine monitor 488
Adjusting rearview camera angle 559
Handling voltage circuit of engine controller 561
Handling battery disconnect switch 562
Testing diodes 563
Pm clinic 564
Pm Clinic service 564
40 Troubleshooting 575
Table of contents 576
General information on troubleshooting 583
Troubleshooting points 583
Sequence of events in troubleshooting 585
Testing before troubleshooting 587
Inspection procedure before troubleshooting 589
Preparation work for troubleshooting of electrical system 608
Classification and procedure for troubleshooting 612
Symptom of probable failure and troubleshooting No 615
Information in troubleshooting table 618
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 620
Connector list and layout 622
Connector contact identification 633
T-branch box and T-branch adapter table 669
Fuse location table 675
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 677
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) 680
Fabrication of short-circuit connector (for CA1883 and CA3135) 681
Failure codes table 682
Troubleshooting by failure code (Display of code) 691
Failure code [879AKA] A/C Inner Sensor Open Circuit 691
Failure code [879AKB] A/C Inner Sensor Short Circuit 692
Failure code [879BKA] A/C Outer Sensor Open Circuit 693
Failure code [879BKB] A/C Outer Sensor Short Circuit 694
Failure code [879CKA] Ventilating Sensor Open Circuit 695
Failure code [879CKB] Ventilating Sensor Short Circuit 696
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 697
Failure code [879EMC] Ventilation Damper Abnormality 698
Failure code [879FMC] Air Mix Damper Abnormality 699
Failure code [879GKX] Refrigerant Abnormality 700
Failure code [989L00] Engine Controller Lock Caution1 701
Failure code [989M00] Engine Controller Lock Caution2 702
Failure code [989N00] Engine Controller Lock Caution3 703
Failure code [A1U0N3] HC Desorb Request 1 704
Failure code [A1U0N4] HC Desorb Request 2 706
Failure code [AA10NX] Air Cleaner Clogging 708
Failure code [AB00KE] Charge Voltage Low 710
Circuit diagram related to charging 711
Failure code [B@BAZG] Engine Oil Pressure Low 712
Failure code [B@BAZK] Eng Oil Level Low 713
Failure code [B@BCNS] Engine Coolant Overheat 714
Failure code [B@BCZK] Radiator Coolant Level Low 715
Circuit diagram related to radiator coolant level switch 716
Failure code [B@HANS] Hyd Oil Overheat 717
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 718
Failure code [CA122] Chg Air Press Sensor High Error 719
Failure code [CA123] Chg Air Press Sensor Low Error 721
Failure code [CA131] Throttle Sensor High Error 723
Circuit diagram related to throttle sensor 724
Failure code [CA132] Throttle Sensor Low Error 725
Circuit diagram related to throttle sensor 726
Failure code [CA144] Coolant Temp Sens High Error 727
Failure code [CA145] Coolant Temp Sens Low Error 729
Failure code [CA153] Chg Air Temp Sensor High Error 731
Failure code [CA154] Chg Air Temp Sensor Low Error 733
Failure code [CA187] Sensor 2 Supply Volt Low Error 735
Failure code [CA221] Ambient Press Sensor High Error 737
Failure code [CA222] Ambient Press Sensor Low Error 739
Failure code [CA227] Sensor 2 Supply Volt High Error 741
Failure code [CA234] Eng Overspeed 742
Failure code [CA238] Ne Speed Sensor Supply Volt Error 743
Failure code [CA239] Ne Speed Sens Supply Volt High Error 744
Circuit diagram related to Ne speed sensor 744
Failure code [CA271] IMV/PCV1 Short Error 745
Failure code [CA272] IMV/PCV1 Open Error 747
Failure code [CA295] Ambient Press Sens In Range Error 749
Failure code [CA322] Inj #1(L#1) Open/Short Error 750
Failure code [CA323] Inj #5(L#5) Open/Short Error 752
Failure code [CA324] Inj #3(L#3) Open/Short Error 754
Failure code [CA325] Inj #6(L#6) Open/Short Error 756
Failure code [CA331] Inj #2(L#2) Open/Short Error 758
Failure code [CA332] Inj #4(L#4) Open/Short Error 760
Failure code [CA343] ECM Critical Internal Failure 763
Failure code [CA351] Injectors Drive Circuit Error 764
Failure code [CA352] Sensor 1 Supply Volt Low Error 765
Failure code [CA356] Mass Air Flow Sensor High Error 767
Failure code [CA357] Mass Air Flow Sensor Low Error 769
Failure code [CA386] Sensor 1 Supply Volt High Error 771
Failure code [CA428] Water in Fuel Sensor High Error 772
Failure code [CA429] Water in Fuel Sensor Low Error 774
Failure code [CA435] Eng Oil Press Sw Error 776
Circuit diagram related to engine oil pressure switch 776
Failure code [CA441] Battery Voltage Low Error 777
Circuit diagram related to engine controller power supply 778
Failure code [CA442] Battery Voltage High Error 779
Failure code [CA449] Rail Press Very High Error 780
Failure code [CA451] Rail Press Sensor High Error 781
Failure code [CA452] Rail Press Sensor Low Error 783
Failure code [CA488] Chg Air Temp High Torque Derate 785
Failure code [CA515] Rail Press Sens Sup Volt High Error 786
Failure code [CA516] Rail Press Sens Sup Volt Low Error 788
Failure code [CA553] Rail Press High Error 790
Failure code [CA555] Crankcase Press High Error 1 791
Failure code [CA556] Crankcase Press High Error 2 792
Failure code [CA559] Rail Press Low Error 793
Failure code [CA595] Turbo Speed High Error 2 795
Failure code [CA687] Turbo Speed Low Error 796
Failure code [CA689] Eng Ne Speed Sensor Error 798
Failure code [CA691] Intake Air Temp Sens High Error 800
Failure code [CA692] Intake Air Temp Sens Low Error 802
Failure code [CA697] ECM Int Temp Sensor High Error 804
Failure code [CA698] ECM Int Temp Sensor Low Error 805
Failure code [CA731] Eng Bkup Speed Sens Phase Error 806
Failure code [CA778] Eng Bkup Speed Sensor Error 808
Failure code [CA1117] Persistent Data Lost Error 813
Failure code [CA1664] KDOC Malfunction 814
Failure code [CA1691] Regeneration Ineffective 816
Failure code [CA1695] Sensor 5 Supply Volt High Error 819
Circuit diagram related to KDPF differential pressure sensor and KDPF outlet pressure sensor 820
Failure code [CA1696] Sensor 5 Supply Volt Low Error 821
Circuit diagram related to KDPF differential pressure sensor and KDPF outlet pressure sensor 822
Failure code [CA1843] Crankcase Press Sens High Error 823
Failure code [CA1844] Crankcase Press Sens Low Error 825
Failure code [CA1879] KDPF Delta P Sensor High Error 827
Failure code [CA1881] KDPF Delta P Sensor Low Error 829
Failure code [CA1883] KDPF Delta P Sens In Range Error 831
Failure code [CA1921] KDPF Soot Load High Error 1 834
Failure code [CA1922] KDPF Soot Load High Error 2 837
Failure code [CA1942] Crankcase Press Sens In Range Error 842
Failure code [CA1993] KDPF Delta Pressure Low Error 843
Failure code [CA2185] Throt Sensor Sup Volt High Error 846
Failure code [CA2186] Throt Sensor Sup Volt Low Error 848
Failure code [CA2249] Rail Press Very Low Error 850
Failure code [CA2271] EGR Valve Pos Sens High Error 851
Failure code [CA2272] EGR Valve Pos Sens Low Error 853
Failure code [CA2288] Turbo Speed High Error 1 856
Failure code [CA2311] IMV Solenoid Error 857
Failure code [CA2349] EGR Valve Solenoid Open Error 858
Failure code [CA2353] EGR Valve Solenoid Short Error 860
Failure code [CA2357] EGR Valve Servo Error 862
Failure code [CA2373] Exhaust Manifold Press Sens High error 863
Failure code [CA2374] Exhaust Manifold Press Sens Low error 865
Failure code [CA2375] EGR Orifice Temp Sens High Error 867
Failure code [CA2376] EGR Orifice Temp Sens Low Error 869
Circuit diagram related to EGR orifice temperature sensor 870
Failure code [CA2381] KVGT Pos Sens High Error 871
Failure code [CA2382] KVGT Pos Sens Low Error 873
Failure code [CA2383] KVGT Solenoid Open Error 876
Failure code [CA2386] KVGT Solenoid Short Error 878
Failure code [CA2387] KVGT Servo Error 880
Failure code [CA2554] Exh Manifold Press Sens In Range Error 881
Failure code [CA2555] Grid Htr Relay Volt Low Error 882
Failure code [CA2556] Grid Htr Relay Volt High Error 884
Failure code [CA2637] KDOC Face Plugging 886
Failure code [CA2639] Manual Stationary Regeneration Request 888
Failure code [CA2961] EGR Orifice Temp High Error 1 891
Failure code [CA2973] Chg Air Press Sensor In Range Error 892
Failure code [CA3133] KDPF Outlet Press Sens High Error 893
Failure code [CA3134] KDPF Outlet Press Sens Low Error 895
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 897
Failure code [CA3251] KDOC Inlet Temp High Error 901
Failure code [CA3253] KDOC Temp Error Non Regeneration 904
Failure code [CA3254] KDOC Outlet Temp High Error 1 907
Failure code [CA3255] KDPF Temp Error Non Regeneration 910
Failure code [CA3256] KDPF Outlet Temp High Error 1 913
Failure code [CA3311] KDOC Outlet Temp High Error 2 916
Failure code [CA3312] KDPF Outlet Temp High Error 2 919
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 922
Failure code [CA3314] KDOC Inlet Temp Sens High Error 925
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 929
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 933
Failure code [CA3317] KDOC Outlet Temp Sens High Error 936
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 940
Failure code [CA3319] KDPF Outlet Temp Sens High Error 944
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 948
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 951
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 955
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 957
Failure code [CA3741] Rail Press Valve Trip Error 959
Failure code [D110KB] Battery Relay Output Voltage 960
Circuit diagram related to battery relay 961
Failure code [D19JKZ] Personal Code Relay Abnormality 962
Failure code [D811MC] KOMTRAX Error 965
Failure code [D862KA] GPS Antenna Open Circuit 966
Figure of structure 966
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) 967
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) 969
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 970
Failure code [DA20MC] Pump Controller 971
Failure code [DA22KK] Pump Solenoid Power Low Error 972
Circuit diagram related to solenoid power supply 973
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 974
Failure code [DA29KQ] Model Selection Abnormality 977
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) 979
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) 981
Failure code [DA2QKR] CAN2 Discon (Pump Con) 982
Failure code [DA2RKR] CAN1 Discon (Pump Con) 985
Failure code [DAF0MB] Monitor ROM Abnormality 986
Failure code [DAF0MC] Monitor Error 987
Failure code [DAF8KB] Camera Power Supply Short Circuit 988
Circuit diagram related to camera power supply 989
Failure code [DAF9KQ] Model Selection Abnormality 990
Failure code [DAFGMC] GPS Module Error 991
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) 992
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) 994
Failure code [DAFQKR] CAN2 Discon (Monitor) 995
Failure code [DAZ9KQ] A/C Model Selection Abnormality 996
Failure code [DAZQKR] CAN2 Discon (AC) 997
Failure code [DB2QKR] CAN2 Discon (Engine Con)1002
Failure code [DB2RKR] CAN1 Discon (Engine Con)1007
Circuit diagram related to CAN communication line 11010
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality1011
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality1013
Failure code [DFB3L8] Service Lever 1 Potentio Error1015
Failure code [DFB4L8] Service Lever 2 Potentio Error1016
Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality1017
Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality1019
Failure code [DGH2KB] Hyd Oil Sensor Short1021
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit1023
Circuit diagram related to air cleaner clogging1023
Failure code [DHPAMA] F Pump Press Sensor Abnormality1024
Circuit diagram related to front pump pressure sensor1026
Failure code [DHPBMA] R Pump Press Sensor Abnormality1027
Circuit diagram related to rear pump pressure sensor1029
Failure code [DHS3MA] Arm IN PPC Sen Abnormality1030
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality1032
Circuit diagram related to bucket CURL PPC pressure sensor1034
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality1035
Circuit diagram related to boom RAISE PPC pressure sensor1037
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality1038
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality1041
Circuit diagram related to swing RIGHT PPC pressure sensor1043
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality1044
Circuit diagram related to swing LEFT PPC pressure sensor1046
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality1047
Circuit diagram related to arm DUMP (arm OUT) PPC pressure sensor1049
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality1050
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality1053
Circuit diagram related to travel PPC pressure sensor1055
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality1056
Circuit diagram related to travel PPC pressure sensor1058
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality1059
Circuit diagram related to travel PPC pressure sensor1061
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality1062
Circuit diagram related to travel PPC pressure sensor1064
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)1065
Failure code [DKR0MA] F pump S/P sensor Abnormality1067
Failure code [DKR1MA] R pump S/P sensor Abnormality1069
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality1071
Circuit diagram related to camera1072
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality1073
Circuit diagram related to camera1074
Failure code [DV20KB] Travel Alarm Short Circuit1075
Circuit diagram related to travel alarm1076
Failure code [DW43KA] Travel Speed Sol Open Circuit1077
Failure code [DW43KB] Travel Speed Sol Short Circuit1079
Circuit diagram related to travel speed solenoid1080
Failure code [DW45KA] Swing holding brake Sol Open Circuit1081
Failure code [DW45KB] Swing holding brake Sol Short Circuit1084
Failure code [DW91KA] Travel Junction Sol Open Circuit1087
Circuit diagram related to travel junction valve solenoid1088
Failure code [DW91KB] Travel Junction Sol Short Circuit1089
Circuit diagram related to travel junction valve solenoid1090
Failure code [DWA2KA] Attachment Sol Open Circuit1091
Circuit diagram related to ATT 1–way/2–way selector solenoid1092
Failure code [DWA2KB] Attachment Sol Short Circuit1093
Circuit diagram related to ATT 1–way/2–way selector solenoid1094
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit1095
Circuit diagram related to 2-stage relief solenoid1096
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit1097
Failure code [DWK2KA] Variable Back Press Sol Open Circuit1099
Circuit diagram related to variable back pressure solenoid1100
Failure code [DWK2KB] Variable Back Press Sol Short Circuit1101
Circuit diagram related to variable back pressure solenoid1102
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit1103
Circuit diagram related to swing cut-off solenoid1104
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit1105
Circuit diagram related to swing cut-off solenoid1106
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit1107
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit1109
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit1111
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit1113
Failure code [DXE0KA] LS-EPC Sol Open Circuit1115
Failure code [DXE0KB] LS-EPC Sol Short Circuit1117
Failure code [DXE4KA] Attachment Flow EPC Open Circuit1119
Circuit diagram related to service flow throttle EPC1120
Failure code [DXE4KB] Attachment Flow EPC Short Circuit1121
Circuit diagram related to service flow throttle EPC1122
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit1123
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit1125
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit1127
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit1129
Failure code [DXEAKA] Service Current EPC1 Discon1131
Failure code [DXEAKB] Service Current EPC1 Short1133
Failure code [DXE7KA] Service Current EPC2 Discon1135
Failure code [DXE7KB] Service Current EPC2 Short1137
Failure code [DXE8KA] Service Current EPC3 Discon1139
Failure code [DXE8KB] Service Current EPC3 Short1141
Failure code [DXE9KA] Service Current EPC4 Discon1143
Failure code [DXE9KB] Service Current EPC4 Short1145
Failure code [DY20KA] Wiper Working Abnormality1147
Circuit diagram related to wiper1148
Failure code [DY20MA] Wiper Parking Abnormality1149
Circuit diagram related to wiper1150
Failure code [DY2CKB] Washer Drive Short Circuit1151
Circuit diagram related to window washer motor1152
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit1153
Circuit diagram related to wiper1154
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit1155
Circuit diagram related to wiper1156
Troubleshooting of electrical system (E-mode)1157
E-1 Engine does not start (Engine does not crank)1157
E-2 Manual preheating system does not work1163
Circuit diagram related to preheating of engine1165
E-3 Automatic preheating system does not work1166
Circuit diagram related to preheating of engine1167
E-4 Preheating monitor does not light up when preheater is operated1168
Circuit diagram related to preheating of engine1169
E-5 When starting switch is turned to ON position, machine monitor displays nothing1170
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow1173
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow1174
E-8 Coolant temperature monitor lights up in white while engine is running1175
E-9 Hydraulic oil temperature monitor lights up in white while engine is running1176
E-10 Charge level monitor lights up while engine is running1177
E-11 Fuel level monitor lights up in red while engine is running1178
E-12 Air cleaner clogging monitor lights up in yellow while engine is running1179
E-13 Water separator monitor lights up while engine is running1180
E-14 Coolant temperature monitor lights up in red while engine is running1181
E-15 Hydraulic oil temperature monitor lights up in red while engine is running1182
E-16 Engine oil pressure monitor lights up in red while engine is running1183
E-17 Fuel gauge indicates either full or empty and does not move1184
Circuit diagram related to fuel level sensor1184
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)1185
Fuel level gauge and fuel level monitor1185
E-19 Coolant temperature gauge indicates either Min or Max and does not move1186
Engine coolant temperature gauge and engine coolant temperature monitor1186
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max)1187
Engine coolant temperature gauge and engine coolant temperature monitor1187
E-21 Hydraulic oil temperature gauge indicates either Min or Max and does not move1188
Circuit diagram related to hydraulic oil temperature sensor1189
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max)1190
Hydraulic oil temperature gauge and hydraulic oil temperature monitor1190
E-23 Content of display on machine monitor is different from that of actual machine1191
E-24 Machine monitor does not display some items1192
E-25 Function switch does not work1193
E-26 Automatic preheating system does not work (In cold season)1194
Engine coolant temperature gauge and engine coolant temperature monitor1194
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated1195
E-28 Auto-deceleration is not actuated or canceled when lever is operated1196
E-29 Working mode selection screen is not diplayed when working mode switch is operated1197
E-30 Engine or hydraulic pump setting does not change when working mode is changed1198
E-31 Travel speed monitor does not change when travel speed switch is operated1199
Circuit diagram related to travel speed solenoid1199
E-32 Travel speed does not change while travel speed selection is changed1200
E-33 Alarm buzzer does not stop sounding1201
E-34 When starting switch is turned to OFF position, service meter is not displayed1202
E-35 Service mode cannot be selected1203
E-36 Any of work equipment, swing and travel does not work1204
Related circuit diagram1205
E-37 Any of work equipment, swing and travel cannot be locked1206
E-38 Machine cannot swing while swing brake cancel switch is canceled1207
E-39 Swing brake does not operate while swing brake cancel switch is locked1209
E-40 One-touch power maximizing function does not work or monitor is not displayed1211
Circuit diagram related to one-touch power maximizing switch1212
E-41 One-touch power maximizing function cannot be canceled1213
E-42 Travel alarm does not sound when machine travels1214
Circuit diagram related to travel alarm1214
E-43 Alarm does not stop sounding while machine is stopped1215
E-44 Horn does not sound1216
Circuit diagram related to horn1217
E-45 Horn does not stop sounding1218
Circuit diagram related to horn1218
E-46 Wiper monitor does not light up or go out when wiper switch is operated1219
E-47 Wiper does not operate when wiper switch is operated1220
Circuit diagram related to wiper1221
E-48 Window washer does not operate when window washer switch is operated1222
Circuit diagram related to wiper1222
E-49 BOOM LOWER indication is not displayed properly with monitoring function1223
E-50 ARM DUMP indication is not displayed properly with monitoring function1224
E-51 ARM IN indication is not displayed properly with monitoring function1225
E-52 BOOM RAISE indication is not displayed properly with monitoring function1226
E-53 BUCKET CURL indication is not displayed properly with monitoring function1227
E-54 BUCKET DUMP indication is not displayed properly with monitoring function1228
E-55 SWING indication is not displayed properly with monitoring function1229
E-56 TRAVEL indication is not displayed properly with monitoring function1230
E-57 Service is not displayed properly with monitoring function1231
Circuit diagram related to attachment control pedal PPC oil pressure switch (service pressure switch)1233
E-58 Attachment hydraulic circuit cannot be changed1234
E-59 KOMTRAX system does not operate normally1235
Troubleshooting of hydraulic and mechanical system (H-mode)1237
Information described in troubleshooting table (H-mode)1237
System chart for hydraulic system1238
Failure mode and cause table1240
H-1 All of work equipment, swing and travel operation lacks speed or power1248
H-2 Engine speed drops significantly or engine stalls1251
H-3 All work equipment, swing and travel does not work1254
H-4 Unusual sound is heard from around hydraulic pump1255
H-5 Fine control performance or response is poor1256
H-6 Boom speed or power is low1258
H-7 Arm speed or power is low1262
H-8 Bucket speed or power is low1267
H-9 Work equipment does not move in single operation1270
H-10 Hydraulic drift of boom is large1271
H-11 Hydraulic drift of arm is large1272
H-12 Hydraulic drift of bucket is large1273
H-13 Time lag of work equipment is large1274
H-14 When part of work equipment is relieved singly, other parts of work equipment move1276
H-15 One-touch power maximizing function does not operate1277
H-16 In combined operation of work equipment, equipment having heavier load moves slower1278
H-17 In combined operations of swing and boom RAISE, boom rising speed is low1279
H-18 In combined operations of swing and travel, travel speed drops largely1280
H-19 Machine does not travel straight1281
H-20 Travel speed is slow1284
H-21 Machine is hard to steer or travel power is low1286
H-22 Travel speed does not change, or travel speed is too slow or fast1289
H-23 One of tracks does not run1290
H-24 Upper structure does not swing to the right or left1292
H-25 Upper structure swing only to the right or left1293
H-26 Swing acceleration or swing speed is low in both directions (right and left)1294
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction1295
H-28 Upper structure overruns excessively when it stops swinging (both right and left)1296
H-29 Upper structure overruns excessively when it stops swinging (either right or left)1297
H-30 Shock is large when upper structure stops swinging1298
H-31 Large unusual noise is heard when upper structure stops swinging1299
H-32 Swing drift on a slope is large while swing holding brake is applied1300
H-33 Swing drift on a slope is large while swing holding brake is released1301
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed1302
H-35 Oil flow in attachment circuit cannot be controlled1303
H-36 Quick coupler cylinder will not extend1304
H-37 Quick coupler cylinder will not extend (but buzzer does not sound)1306
H-38 Buzzer does not sound (but quick coupler cylinder does retract)1308
H-39 Quick coupler cylinder extends and retracts slowly1310
Troubleshooting of engine (S-mode)1311
Information mentioned in troubleshooting table (S mode)1311
S-1 When starting switch is turned to START position, engine does not crank1312
S-2 Engine cranks but no exhaust smoke comes out1313
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)1314
S-4 Engine startability is poor1315
S-5 Engine does not pick up smoothly1317
S-6 Engine stops during operation1319
S-7 Engine runs rough or is unstable1321
S-8 Engine lacks power1322
S-9 Exhaust smoke is black (KDPF clogs up early)1324
S-10 Engine oil consumption is excessive1326
S-11 Engine oil becomes contaminated early1327
S-12 Fuel consumption is excessive1328
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)1329
S-14 Engine oil pressure drops1330
S-15 Fuel is contaminated in engine oil1331
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)1332
S-17 Coolant temperature rises too high (overheating)1333
S-18 Unusual noise is heard1334
S-19 Vibration is excessive1335
S-20 Air cannot be bled from fuel circuit1336
S-21 Active regeneration is executed frequently1337
S-22 Active regeneration takes time1338
S-23 White smoke is exhausted during active regeneration1339
Auto grease system1340
Finding malfunctions1340
Malfunction finding procedures1343
50 Disassembly and assembly1345
Table of contents1346
General information on disassembly and assembly1348
How to read this manual1348
Coating materials list1350
Special tools list1354
Sketches of special tools1359
Engine and cooling system1363
Removal and installation of supply pump assembly1363
Removal and installation of injector assembly1368
Removal and installation of cylinder head assembly1377
Removal and installation of radiator assembly1397
Removal and installation of hydraulic oil cooler assembly1399
Removal and installation of aftercooler assembly1402
Removal and installation of engine and main pump assembly1404
Removal and installation of engine front oil seal1416
Removal and installation of engine rear oil seal1420
Removal and installation of fuel cooler assembly1423
Removal and installation of fuel tank assembly1424
Removal and installation of engine hood assembly1427
Removal and installation of KDPF assembly1430
Disassembly and assembly of KDPF assembly1438
Removal and installation of KCCV assembly1446
Removal and installation of air cleaner assembly1450
Power train1453
Removal and installation of travel motor and final drive assembly1453
Disassembly and assembly of final drive1454
Removal and installation of swing motor and swing machinery assembly1462
Disassembly and assembly of swing machinery1465
Removal and installation of swing circle assembly1472
Undercarriage and frame1473
Separation and connection of track shoe assembly1473
Removal and installation of sprocket1476
Removal and installation of idler and idler cushion assembly1477
Disassembly and assembly of idler assembly1478
Disassembly and assembly of idler cushion1481
Disassembly and assembly of track roller assembly1483
Disassembly and assembly of carrier roller1485
Removal and installation of revolving frame assembly1488
Removal and installation of counterweight assembly1490
Hydraulic system1493
Removal and installation of center swivel joint assembly1493
Disassembly and assembly of center swivel joint1496
Removal and installation of hydraulic tank assembly1497
Removal and installation of main pump assembly1501
Removal and installation of control valve assembly1505
Disassembly and assembly of control valve1512
Disassembly and assembly of work equipment PPC valve1517
Disassembly and assembly of travel PPC valve1519
Removal and installation of quick coupler valve1522
Work equipment1523
Removal and installation of work equipment assembly1523
Disassembly and assembly of work equipment cylinder1526
Cab and its attachments1532
Removal and installation of operator’s cab assembly1532
Removal and installation of operator cab glass (adhered glass)1537
Removal and installation of front window assembly1547
Removal and installation of floor frame assembly1553
Removal and installation of air conditioner unit assembly1559
Removal and installation of operator’s seat1563
Removal and installation of seat belt1565
Removal and installation of front wiper assembly1567
Electrical system1574
Removal and installation of air conditioner compressor assembly1574
Removal and installation of air conditioner condenser assembly1577
Removal and installation of engine controller assembly1579
Removal and installation of pump controller assembly1581
Removal and installation of machine monitor assembly1584
Removal and installation of pump swash plate sensor1586
Removal and installation of mass air flow and temperature sensor1587
Removal and installation of KOMTRAX terminal assembly1588
60 Maintenance standard1591
Table of contents1592
Engine and cooling system1593
Engine mount1593
Cooling system1594
Power train1595
Swing circle1595
Swing machinery1596
Final drive1598
Sprocket1600
Undercarriage and frame1602
Track frame and idler cushion1602
Idler1604
Track roller1606
Carrier roller1607
Track shoe1608
Hydraulic system1614
Hydraulic tank1614
Main pump1615
Control valve1616
Swing motor1626
Travel motor1628
Work equipment and swing PPC valve1631
Travel PPC valve1634
1st-line attachment PPC valve (with EPC valve)1637
2nd-line attachment PPC valve1640
Solenoid valve1642
Hydraulic drift prevention valve1643
Attachment circuit selector valve (for low-pressure circuit)1645
Center swivel joint1646
Work equipment1647
Work equipment1647
Boom cylinder (large diameter piston)1656
Arm cylinder1657
Bucket cylinder1658
80 Appendix1659
Table of contents1660
Air conditioner components1661
Precautions for refrigerant1661
Air conditioner component1662
Configuration and function of refrigeration cycle1665
Outline of refrigeration cycle1666
Air conditioner unit1668
Dual pressure switch1675
Air conditioner controller1676
Compressor1677
Air conditioner condenser1678
Sunlight sensor1680
Outer temperature sensor (outside air temperature sensor)1681
Procedure for testing and troubleshooting1682
Circuit diagram and arrangement of connector pins1684
System diagram1686
Input and output signals of the air conditioner controller1687
Parts and connectors layout1689
Testing air leakage (duct)1693
Testing with self-diagnosis function1696
Testing vent (mode) changeover1698
Testing FRESH/RECIRC air changeover1700
Testing sunlight sensor1701
Testing (dual) pressure switch for refrigerant1702
Testing relays1703
Troubleshooting chart 11704
Troubleshooting chart 21705
Information in troubleshooting table1708
Failure code list related to air conditioner1709
Failure code [879AKA] A/C Inner Sensor Open Circuit1710
Failure code [879AKB] A/C Inner Sensor Short Circuit1711
Failure code [879BKA] A/C Outer sensor Open Circuit1712
Circuit diagram related to air conditioner outside air temperature sensor1713
Failure code [879BKB] A/C Outer sensor Short Circuit1714
Circuit diagram related to air conditioner outside air temperature sensor1715
Failure code [879CKA] Ventilating Sensor Open Circuit1716
Failure code [879CKB] Ventilating Sensor Short Circuit1717
Failure code [879DKZ] Sunlight sensor Open or Short Circuit1718
Circuit diagram related to sunlight sensor1719
Failure code [879EMC] Ventilation Damper Abnormality1720
Failure code [879FMC] Air Mix Damper Abnormality1721
Failure code [879GKX] Refrigerant Abnormality1722
Circuit diagram related to (dual) pressure switch for refrigerant1722
A-1 Troubleshooting for power supply system (Air conditioner does not operate)1723
Circuit diagram related to power supply1724
A-2 Troubleshooting of compressor system (Air is not cooled)1725
Circuit diagram related to compressor and refrigerant system1727
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1728
Circuit diagram related to blower motor system1729
A-4 Troubleshooting for FRESH/RECIRC air changeover1730
Circuit diagram related to FRESH/RECIRC air changeover1731
Troubleshooting with gauge pressure1732
Connection of service tool1735
Precautions for disconnecting and connecting air conditioner piping1737
Handling of compressor oil1739
Desiccant replacement1741
90 Diagrams and drawings1745
Table of contents1746
Hydraulic circuit diagram1747
Symbols in hydraulic circuit diagram1747
Electric circuit diagram1751
Symbols in electric circuit diagram1751
A1765
B1765
C1765
D1765
E1765
F1766
H1770
I1771
K1771
L1771
M1771
O1772
P1772
Q1772
R1772
S1772
T1773
V1773
W1773

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24