Komatsu Hydraulic Excavator PC290LC-10 Shop Manual SEN05644-08 PDF

Description

Komatsu Hydraulic Excavator PC290LC-10 Shop Manual SEN05644-08 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC290LC-10 Shop Manual SEN05644-08 – PDF DOWNLOAD

Language : English
Pages :1646
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC290LC-10 Shop Manual SEN05644-08 – PDF DOWNLOAD

SERIAL NUMBERS 15001 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 2 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, lift truck, service vehicle, 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 PC290LC-10 Shop Manual SEN05644-08 – PDF DOWNLOAD

SERIAL NUMBERS 15001 and up

Cover 1
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 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
01 Specification 67
Table of contents 68
Specifications 69
Specification drawings 69
Working range drawings 70
Specifications 71
Weight table 74
Table of fuel, coolant and lubricants 75
10 Structure and function 77
Table of contents 78
Engine and cooling system 79
Engine related parts 79
KVGT 81
EGR system piping drawing 88
EGR system circuit diagram 90
EGR valve 92
EGR cooler 94
KCCV layout drawing 96
KCCV ventilator 98
KDPF 100
Cooling system 104
Power train 106
Power train system 106
Swing circle 108
Swing machinery 109
Final drive 111
Undercarriage and frame 113
Track frame and idler cushion 113
Hydraulic system 115
Hydraulic equipment layout drawing 115
Valve control 117
Hydraulic tank 119
CLSS 121
Main pump 126
Control valve 150
Swing motor 204
Travel motor 215
PPC valve 229
Solenoid valve 250
Attachment circuit selector valve (for high pressure circuit) 253
Attachment circuit selector valve (for low pressure circuit) 255
Center swivel joint 258
Accumulator 260
Work equipment 261
Work equipment 261
Work equipment shim 262
Bucket play adjustment shim 263
Cab and its attachments 264
Cab mount and cab tipping stopper 264
ROPS cab 265
Electrical system 266
Electrical control system 266
Machine monitor system 310
KOMTRAX system 330
Sensor 332
20 Standard value tables 351
Table of contents 352
Standard service value table 353
Standard value table for engine related parts 353
Standard value table for chassis related parts 355
30 Testing and adjusting 369
Table of contents 370
Related information on testing and adjusting 371
Tools for testing and adjusting 371
Sketch of tools for testing and adjusting 375
Engine and cooling system 377
Testing engine speed 377
Testing boost pressure 378
Testing exhaust gas color 379
Testing and adjusting valve clearance 381
Testing compression pressure 384
Measuring blowby pressure 388
Measuring engine oil pressure 389
Measuring EGR valve and KVGT oil pressure 390
Measuring fuel pressure 391
Measuring fuel delivery, return and leakage 397
Bleeding air from fuel system 402
Testing fuel circuit for leakage 404
Handling cylinder cutout mode operation 405
Handling no-injection cranking operation 406
Testing and adjusting air conditioner compressor belt tension 407
Replacing fan belt 408
Power train 409
Testing swing circle bearing clearance 409
Undercarriage and frame 410
Testing and adjusting track tension 410
Hydraulic system 411
Releasing remaining pressure from hydraulic circuit 411
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits 412
Testing oil pressure in control circuit 416
Testing and adjusting oil pressure in pump PC control circuit 417
Testing and adjusting oil pressure in pump LS control circuit 420
Testing output pressure of solenoid valve 425
Measuring PPC valve output pressure 429
Adjusting play of work equipment and swing PPC valves 431
Testing pump swash plate sensor 432
Isolating the parts causing hydraulic drift in work equipment 433
Testing oil leakage 435
Bleeding air from hydraulic circuit 438
Cab and its attachments 440
Testing cab tipping stopper 440
Adjusting mirrors 441
Electrical system 443
Special functions of machine monitor 443
Adjusting rearview camera angle 509
Handling voltage circuit of engine controller 511
Handling battery disconnect switch 512
Testing diodes 513
Pm clinic 514
Pm clinic service 514
40 Troubleshooting 525
Table of contents 526
Related information on troubleshooting 533
Troubleshooting points 533
Sequence of events in troubleshooting 535
Testing before troubleshooting 537
Inspection procedure before troubleshooting 539
Preparation work for troubleshooting of electrical system 567
Classification and procedure for troubleshooting 571
Symptom of probable failure and troubleshooting No 574
Information in troubleshooting table 577
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 579
Connector list and layout 581
Connector contact identification 592
T-branch box and T-branch adapter table 631
Fuse list and location 636
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 638
Failure codes table 641
Troubleshooting by failure code (Display of code) 650
Failure code [879AKA] A/C Inner Sensor Open Circuit 650
Failure code [879AKB] A/C Inner Sensor Short Circuit 651
Failure code [879BKA] A/C Outer Sensor Open Circuit 652
Failure code [879BKB] A/C Outer Sensor Short Circuit 653
Failure code [879CKA] Ventilating Sensor Open Circuit 654
Failure code [879CKB] Ventilating Sensor Short Circuit 655
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 656
Failure code [879EMC] Ventilation Damper Abnormality 657
Failure code [879FMC] Air Mix Damper Abnormality 658
Failure code [879GKX] Refrigerant Abnormality 659
Failure code [989L00] Engine Controller Lock Caution1 660
Failure code [989M00] Engine Controller Lock Caution2 661
Failure code [989N00] Engine Controller Lock Caution3 662
Failure code [A1U0N3] HC desorb request1 663
Failure code [A1U0N4] HC desorb request2 665
Failure code [AA10NX] Air Cleaner Clogging 667
Failure code [AB00KE] Charge Voltage Low 669
Failure code [B@BAZG] Engine Oil Pressure Low 671
Failure code [B@BAZK] Eng Oil Level Low 672
Failure code [B@BCNS] Engine Coolant Overheat 673
Failure code [B@BCZK] Radiator Coolant Level Low 674
Failure code [B@HANS] Hyd Oil Overheat 676
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 677
Failure code [CA122] Chg Air Press Sensor High Error 678
Failure code [CA123] Chg Air Press Sensor Low Error 680
Failure code [CA131] Throttle Sensor High Error 682
Failure code [CA132] Throttle Sensor Low Error 684
Failure code [CA144] Coolant Temp Sens High Error 686
Failure code [CA145] Coolant Temp Sens Low Error 688
Failure code [CA153] Chg Air Temp Sensor High Error 690
Failure code [CA154] Chg Air Temp Sensor Low Error 692
Failure code [CA187] Sensor 2 Supply Volt Low Error 694
Failure code [CA221] Ambient Press Sensor High Error 696
Failure code [CA222] Ambient Press Sensor Low Error 698
Failure code [CA227] Sensor 2 Supply Volt High Error 700
Failure code [CA234] Eng Overspeed 701
Failure code [CA238] Ne Speed Sensor Supply Volt Error 702
Failure code [CA239] Ne Speed Sens Supply Volt High Error 703
Failure code [CA271] IMV/PCV1 Short Error 704
Failure code [CA272] IMV/PCV1 Open Error 706
Failure code [CA295] Ambient Press Sens In Range Error 707
Failure code [CA322] Inj #1(L#1) Open/Short Error 708
Failure code [CA323] Inj #5(L#5) Open/Short Error 710
Failure code [CA324] Inj #3(L#3) Open/Short Error 712
Failure code [CA325] Inj #6(L#6) Open/Short Error 714
Failure code [CA331] Inj #2(L#2) Open/Short Error 716
Failure code [CA332] Inj #4(L#4) Open/Short Error 718
Failure code [CA343] ECM Critical Internal Failure 720
Failure code [CA351] Injectors Drive Circuit Error 721
Failure code [CA352] Sensor 1 Supply Volt Low Error 722
Failure code [CA356] Mass Air Flow Sensor High Error 724
Failure code [CA357] Mass Air Flow Sensor Low Error 726
Failure code [CA386] Sensor 1 Supply Volt High Error 728
Failure code [CA428] Water in Fuel Sensor High Error 729
Failure code [CA429] Water in Fuel Sensor Low Error 731
Failure code [CA435] Eng Oil Press Sw Error 733
Failure code [CA441] Battery Voltage Low Error 734
Failure code [CA442] Battery Voltage High Error 736
Failure code [CA449] Rail Press Very High Error 737
Failure code [CA451] Rail Press Sensor High Error 738
Failure code [CA452] Rail Press Sensor Low Error 740
Failure code [CA488] Chg Air Temp High Torque Derate 741
Failure code [CA515] Rail Press Sens Sup Volt High Error 742
Failure code [CA516] Rail Press Sens Sup Volt Low Error 744
Failure code [CA553] Rail Press High Error 746
Failure code [CA555] Crankcase Press High Error 1 747
Failure code [CA556] Crankcase Press High Error 2 748
Failure code [CA559] Rail Press Low Error 749
Failure code [CA595] Turbo Speed High Error 2 751
Failure code [CA687] Turbo Speed Low Error 752
Failure code [CA689] Eng Ne Speed Sensor Error 754
Failure code [CA691] Intake Air Temp Sens High Error 756
Failure code [CA692] Intake Air Temp Sens Low Error 758
Failure code [CA697] ECM Int Temp Sensor High Error 760
Failure code [CA698] ECM Int Temp Sensor Low Error 761
Failure code [CA731] Eng Bkup Speed Sens Phase Error 762
Failure code [CA778] Eng Bkup Speed Sensor Error 763
Failure code [CA1117] Persistent Data Lost Error 767
Failure code [CA1664] KDOC Malfunction 768
Failure code [CA1691] Regeneration Ineffective 770
Failure code [CA1695] Sensor 5 Supply Volt High Error 772
Failure code [CA1696] Sensor 5 Supply Volt Low Error 774
Failure code [CA1843] Crankcase Press Sens High Error 776
Failure code [CA1844] Crankcase Press Sens Low Error 778
Failure code [CA1879] KDPF Delta P Sensor High Error 780
Failure code [CA1881] KDPF Delta P Sensor Low Error 782
Failure code [CA1883] KDPF Delta P Sens In Range Error 784
Failure code [CA1921] KDPF Soot Load High Error 1 787
Failure code [CA1922] KDPF Soot Load High Error 2 789
Failure code [CA1942] Crankcase Press Sens In Range Error 794
Failure code [CA1993] KDPF Delta Pressure Low Error 795
Failure code [CA2185] Throt Sensor Sup Volt High Error 796
Failure code [CA2186] Throt Sensor Sup Volt Low Error 797
Failure code [CA2249] Rail Press Very Low Error 798
Failure code [CA2271] EGR Valve Pos Sens High Error 799
Failure code [CA2272] EGR Valve Pos Sens Low Error 801
Failure code [CA2288] Turbo Speed High Error 1 804
Failure code [CA2311] IMV Solenoid Error 805
Failure code [CA2349] EGR Valve Solenoid Open Error 806
Failure code [CA2353] EGR Valve Solenoid Short Error 808
Failure code [CA2357] EGR Valve Servo Error 810
Failure code [CA2373] Exh Manifold Press Sens Volt 811
Failure code [CA2374] Exhaust Manifold Press Sens Low Error 813
Failure code [CA2375] EGR Orifice Temp Sens High Error 815
Failure code [CA2376] EGR Orifice Temp Sens Low Error 817
Failure code [CA2381] KVGT Pos Sens High Error 819
Failure code [CA2382] KVGT Pos Sens Low Error 821
Failure code [CA2383] KVGT Solenoid Open Error 823
Failure code [CA2386] KVGT Solenoid Short Error 825
Failure code [CA2387] KVGT Servo Error 827
Failure code [CA2554] Exh Manifold Press Sens In Range Error 828
Failure code [CA2555] Grid Htr Relay Volt Low Error 829
Failure code [CA2556] Grid Htr Relay Volt High Error 832
Failure code [CA2637] KDOC Face Plugging 834
Failure code [CA2639] Manual Stationary Regeneration Request 836
Failure code [CA2961] EGR Orifice Temp High Error 1 838
Failure code [CA2973] Chg Air Press Sensor In Range Error 839
Failure code [CA3133] KDPF Outlet Press Sens High Error 840
Failure code [CA3134] KDPF Outlet Press Sens Low Error 842
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 844
Failure code [CA3251] KDOC Inlet Temp High Error 847
Failure code [CA3253] KDOC Temp Error – Non Regeneration 850
Failure code [CA3254] KDOC Outlet Temp High Error 1 852
Failure code [CA3255] KDPF Temp Error – Non Regeneration 855
Failure code [CA3256] KDPF Outlet Temp High Error 1 856
Failure code [CA3311] KDOC Outlet Temp High Error 2 857
Failure code [CA3312] KDPF Outlet Temp High Error 2 858
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 860
Failure code [CA3314] KDOC Inlet Temp Sens High Error 863
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 867
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 871
Failure code [CA3317] KDOC Outlet Temp Sens High Error 874
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error 878
Failure code [CA3319] KDPF Outlet Temp Sens High Error 882
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 886
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 889
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 893
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 894
Failure code [CA3741] Rail Press Valve Trip Error 896
Failure code [D110KB] Battery Relay Output Voltage 897
Failure code [D19JKZ] Personal Code Relay Abnormality 899
Failure code [D811MC] KOMTRAX Error 902
Failure code [D862KA] GPS Antenna Open Circuit 903
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 904
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 906
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 907
Failure code [DA20MC] Pump Controller 908
Failure code [DA22KK] Pump Solenoid Power Low Error 909
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 911
Failure code [DA29KQ] Model Selection Abnormality 914
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 916
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 918
Failure code [DA2QKR] CAN2 Discon (Pump Con) 919
Failure code [DA2RKR] CAN1 Discon (Pump Con) 921
Failure code [DAF0MB] Monitor ROM Abnormality 922
Failure code [DAF0MC] Monitor Error 923
Failure code [DAF8KB] Camera Power Supply Short Circuit 924
Failure code [DAF9KQ] Model Selection Abnormality 926
Failure code [DAFGMC] GPS Module Error 927
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 928
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 930
Failure code [DAFQKR] CAN2 Discon (Monitor) 931
Failure code [DAZ9KQ] A/C Model Selection Abnormality 932
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 933
Failure code [DB2QKR] CAN2 Discon (Engine Con) 937
Failure code [DB2RKR] CAN1 Discon (Engine Con) 942
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 946
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 948
Failure code [DHPAMA] F Pump Press Sensor Abnormality 949
Failure code [DHPBMA] R Pump Press Sensor Abnormality 952
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 955
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 957
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 960
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality 963
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 966
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 969
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality 972
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 975
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 978
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 981
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 984
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 987
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality 990
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality 993
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 996
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 998
Failure code [DV20KB] Travel Alarm Short Circuit 1000
Failure code [DW43KA] Travel Speed Sol Open Circuit 1002
Failure code [DW43KB] Travel Speed Sol Short Circuit 1004
Failure code [DW45KA] Swing Brake Sol Open Circuit 1006
Failure code [DW45KB] Swing Brake Sol Short Circuit 1009
Failure code [DW91KA] Travel Junction Sol Open Circuit 1012
Failure code [DW91KB] Travel Junction Sol Short Circuit 1014
Failure code [DWA2KA] Attachment Sol Open Circuit 1016
Failure code [DWA2KB] Attachment Sol Short Circuit 1018
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit 1020
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 1022
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1024
Failure code [DWK2KB] Variable Back Press Sol Short Circuit 1026
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1028
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit 1030
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 1032
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1034
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 1036
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1038
Failure code [DXE0KA] LS-EPC Sol Open Circuit 1040
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1042
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1044
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 1046
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1048
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit 1050
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1052
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit 1054
Failure code [DY20KA] Wiper Working Abnormality 1056
Failure code [DY20MA] Wiper Parking Abnormality 1058
Failure code [DY2CKB] Washer Drive Short Circuit 1060
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 1062
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 1064
Troubleshooting of electrical system (E-mode) 1066
E-1 Engine does not start (Engine does not crank) 1066
E-2 Manual preheating system does not work 1072
E-3 Automatic preheating system does not work 1075
E-4 Preheating monitor does not light up when preheater is operated 1077
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1079
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow 1082
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow 1083
E-8 Coolant temperature monitor lights up in white while engine is running 1084
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1085
E-10 Charge level monitor lights up while engine is running 1086
E-11 Fuel level monitor lights up in red while engine is running 1087
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 1088
E-13 Water separator monitor lights up while engine is running 1089
E-14 Coolant temperature monitor lights up in red while engine is running 1090
E-15 Hydraulic oil temperature monitor lights up in red while engine is running 1091
E-16 Engine oil pressure monitor lights up in red while engine is running 1092
E-17 Fuel gauge indicates either full or empty and does not move 1093
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 1094
E-19 Coolant temperature gauge indicates either Min or Max and does not move 1095
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max) 1096
E-21 Hydraulic oil temperature gauge indicates either Min or Max and does not move 1097
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max) 1099
E-23 Content of display on machine monitor is different from that of actual machine 1100
E-24 Machine monitor does not display some items 1101
E-25 Function switch does not work 1102
E-26 Automatic preheating system does not work (In cold season) 1103
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated 1104
E-28 Auto-deceleration is not actuated or canceled when lever is operated 1105
E-29 Working mode selection screen is not diplayed when working mode switch is operated 1106
E-30 Engine or hydraulic pump setting does not change when working mode is changed 1107
E-31 Travel speed monitor does not change when travel speed switch is operated 1108
E-32 Travel speed does not change when travel speed is shifted 1109
E-33 Alarm buzzer does not stop sounding 1110
E-34 When starting switch is turned to OFF position, service meter is not displayed 1111
E-35 Service mode cannot be selected 1112
E-36 Any of work equipment, swing and travel does not work 1113
E-37 Any of work equipment, swing and travel cannot be locked 1115
E-38 Machine cannot swing while swing brake cancel switch is canceled 1116
E-39 Swing brake does not operate while swing brake cancel switch is locked 1118
E-40 One-touch power maximizing function does not work or monitor is not displayed 1120
E-41 One-touch power maximizing function cannot be released 1122
E-42 Travel alarm does not sound when machine travels 1123
E-43 Travel alarm does not stop sounding when machine stops 1124
E-44 Horn does not sound 1125
E-45 Horn does not stop sounding 1127
E-46 Wiper monitor does not light up or go out when wiper switch is operated 1128
E-47 Wiper does not operate when wiper switch is operated 1129
E-48 Window washer does not operate when window washer switch is operated 1131
E-49 BOOM LOWER indication is not displayed properly with monitoring function 1132
E-50 ARM DUMP indication is not displayed properly with monitoring function 1133
E-51 ARM IN indication is not displayed properly with monitoring function 1134
E-52 BOOM RAISE indication is not displayed properly with monitoring function 1135
E-53 BUCKET CURL indication is not displayed properly with monitoring function 1136
E-54 BUCKET DUMP indication is not displayed properly with monitoring function 1137
E-55 SWING indication is not displayed properly with monitoring function 1138
E-56 TRAVEL indication is not displayed properly with monitoring function 1139
E-57 Service is not displayed properly with monitoring function 1140
E-58 Attachment hydraulic circuit cannot be changed 1143
E-59 KOMTRAX system does not work properly 1144
Troubleshooting of hydraulic and mechanical system (H-mode) 1145
Information described in troubleshooting table (H-mode) 1145
System chart for hydraulic system 1146
Failure mode and cause table 1148
H-1 All of work equipment, swing and travel operation lacks speed or power 1156
H-2 Engine speed lowers significantly or engine stalls 1159
H-3 Any of work equipment, swing and travel does not work 1161
H-4 Unusual sound is heard from around hydraulic pump 1162
H-5 Fine control performance or response is poor 1163
H-6 Boom operation lacks speed or power 1164
H-7 Arm operation lacks speed or power 1166
H-8 Bucket operation lacks speed or power 1168
H-9 Work equipment does not move in single operation 1169
H-10 Hydraulic drift of boom is large 1170
H-11 Hydraulic drift of arm is large 1171
H-12 Hydraulic drift of bucket is large 1172
H-13 Time lag of work equipment is large 1173
H-14 When part of work equipment is relieved singly, other parts of work equipment move 1175
H-15 One-touch power maximizing function does not work 1176
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1177
H-17 In combined operations of swing and boom RAISE, boom rising speed is low 1178
H-18 In combined operations of swing and travel, travel speed drops largely 1179
H-19 Machine does not travel straight 1180
H-20 Travel speed is too low 1181
H-21 Machine is hard to steer or travel power is low 1183
H-22 Travel speed does not change, or travel speed is too low or high 1185
H-23 One of tracks does not run 1186
H-24 Upper structure does not swing to the right or left 1187
H-25 Upper structure swings only to the right or left 1188
H-26 Swing acceleration is poor or swing speed is low (both right and left) 1189
H-27 Swing acceleration is poor or swing speed is low (either right or left) 1190
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1191
H-29 Upper structure overruns excessively when it stops swinging (either right or left) 1192
H-30 Shock is large when upper structure stops swinging 1193
H-31 Large unusual noise is heard when upper structure stops swinging 1194
H-32 Swing drift on a slope is large while swing holding brake is applied 1195
H-33 Swing drift on a slope is large while swing holding brake is released 1196
H-34 Attachment circuit cannot be changed while attachment is installed 1197
H-35 Oil flow in attachment circuit cannot be controlled 1198
Troubleshooting of engine (S-mode) 1199
Information mentioned in troubleshooting table (S mode) 1199
S-1 When starting switch is turned to START position, engine does not crank 1200
S-2 When engine cranks, smoke does not come out 1201
S-3 Engine does not start while fuel is injected (Incomplete combustion) 1202
S-4 Startability is poor 1203
S-5 Engine does not pick up smoothly 1205
S-6 Engine stops during operation 1206
S-7 Engine runs rough or is unstable 1208
S-8 Engine lacks power 1209
S-9 Exhaust smoke is black (KDPF clogs up early) 1211
S-10 Engine oil consumption is too much 1213
S-11 Oil becomes contaminated early 1214
S-12 Fuel consumption is excessive 1215
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1216
S-14 Engine oil pressure drops 1217
S-15 Fuel is contaminated in engine oil 1218
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) 1219
S-17 Coolant temperature rises too high (Overheating) 1220
S-18 Unusual noise is heard 1221
S-19 Vibration is excessive 1222
S-20 Automatic regeneration is operated frequently 1223
S-21 Active regeneration is operated for long 1224
S-22 White smoke comes out in the process of active regeneration 1225
50 Disassembly and assembly 1227
Table of contents 1228
Related information on disassembly and assembly 1230
How to read this manual 1230
Coating materials list 1232
Special tools list 1236
Sketches of special tools 1240
Engine and cooling system 1243
Removal and installation of supply pump assembly 1243
Removal and installation of injector assembly 1248
Removal and installation of cylinder head assembly 1257
Removal and installation of radiator assembly 1277
Removal and installation of hydraulic oil cooler assembly 1279
Removal and installation of aftercooler assembly 1282
Removal and installation of engine and main pump assembly 1284
Removal and installation of engine front oil seal 1296
Removal and installation of engine rear oil seal 1300
Removal and installation of fuel cooler assembly 1303
Removal and installation of fuel tank assembly 1304
Removal and installation of engine hood assembly 1307
Removal and installation of KDPF assembly 1310
Disassembly and assembly of KDPF assembly 1318
Removal and installation of KCCV assembly 1326
Removal and installation of air cleaner assembly 1330
Power train system 1333
Removal and installation of travel motor and final drive assembly 1333
Disassembly and assembly of final drive 1334
Removal and installation of swing motor and swing machinery assembly 1342
Disassembly and assembly of swing machinery 1345
Removal and installation of swing circle assembly 1353
Undercarriage and frame 1354
Separation and connection of track shoe assembly 1354
Removal and installation of sprocket 1356
Removal and installation of idler and idler cushion assembly 1357
Disassembly and assembly of idler 1358
Disassembly and assembly of idler cushion 1361
Disassembly and assembly of track roller 1363
Disassembly and assembly of carrier roller 1365
Removal and installation of revolving frame assembly 1368
Removal and installation of counterweight assembly 1370
Hydraulic system 1373
Removal and installation of center swivel joint assembly 1373
Disassembly and assembly of center swivel joint 1375
Removal and installation of hydraulic tank assembly 1376
Removal and installation of main pump assembly 1380
Removal and installation of control valve assembly 1384
Disassembly and assembly of control valve 1391
Disassembly and assembly of work equipment PPC valve 1398
Disassembly and assembly of travel PPC valve 1400
Work equipment 1403
Removal and installation of work equipment assembly 1403
Disassembly and assembly of work equipment cylinder 1406
Cab and its attachments 1412
Removal and installation of operator’s cab assembly 1412
Removal and installation of operator cab glass (adhered glass) 1417
Removal and installation of front window assembly 1427
Removal and installation of floor frame assembly 1433
Removal and installation of air conditioner unit assembly 1439
Removal and installation of operator’s seat 1443
Removal and installation of seat belt 1445
Removal and installation of front wiper assembly 1447
Electrical system 1454
Removal and installation of air conditioner compressor assembly 1454
Removal and installation of air conditioner condenser assembly 1457
Removal and installation of engine controller assembly 1459
Removal and installation of pump controller assembly 1461
Removal and installation of machine monitor assembly 1464
Removal and installation of pump swash plate sensor 1466
Removal and installation of mass air flow and temperature sensor 1467
Removal and installation of KOMTRAX terminal assembly 1468
60 Maintenance standard 1471
Table of contents 1472
Engine and cooling system 1473
Engine mount 1473
Cooling system 1474
Power train system 1475
Swing circle 1475
Swing machinery 1476
Final drive 1478
Sprocket 1480
Undercarriage and frame 1482
Track frame and idler cushion 1482
Idler 1484
Track roller 1486
Carrier roller 1488
Track shoe 1489
Hydraulic system 1492
Hydraulic tank 1492
Main pump 1493
Control valve 1494
Swing motor 1504
Travel motor 1506
PPC valve 1509
Solenoid valve 1518
Attachment circuit selector valve (for high-pressure circuit) 1519
Attachment circuit selector valve (for low-pressure circuit) 1520
Center swivel joint 1521
Work equipment 1522
Work equipment 1522
Work equipment cylinder 1530
80 Appendix 1533
Table of contents 1534
Air conditioner components 1535
Precautions for refrigerant 1535
Air conditioner component 1536
Configuration and function of refrigeration cycle 1538
Outline of refrigeration cycle 1539
Air conditioner unit 1541
Dual pressure switch 1548
Air conditioner controller 1549
Compressor 1550
Air conditioner condenser 1551
Sunlight sensor 1553
Outer temperature sensor (outside air temperature sensor) 1554
Procedure for testing and troubleshooting 1555
Circuit diagram and arrangement of connector pins 1557
System diagram 1559
Input and output signals of the air conditioner controller 1560
Parts and connectors layout 1562
Layout of air conditioner related parts and connectors 1563
Testing air leakage (duct) 1566
Testing with self-diagnosis function 1569
How to open the electrical system abnormality record screen in service mode of the machine monitor 1570
Testing vent (mode) changeover 1572
Testing FRESH/RECIRC air changeover 1574
Testing sunlight sensor 1575
Testing (dual) pressure switch for refrigerant 1576
Testing relays 1577
Troubleshooting chart 1 1578
Troubleshooting chart 2 1579
Information in troubleshooting table 1582
Failure code list related to air conditioner 1583
Failure code [879AKA] A/C Inner sensor Open Circuit 1584
Failure code [879AKB] A/C Inner sensor Short Circuit 1585
Failure code [879BKA] A/C Outer sensor Open Circuit 1586
Failure code [879BKB] A/C Outer sensor Short Circuit 1588
Failure code [879CKA] Ventilating sensor Open Circuit 1590
Failure code [879CKB] Ventilating sensor Short Circuit 1591
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1592
Failure code [879EMC] Ventilating Damper Abnormality 1594
Failure code [879FMC] Air Mix Damper Abnormality 1595
Failure code [879GKX] Refrigerant Abnormality 1596
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1597
A-2 Troubleshooting of compressor system (Air is not cooled) 1599
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1602
A-4 Troubleshooting for FRESH/RECIRC air changeover 1604
Troubleshooting with gauge pressure 1606
Testing refrigerant pressure 1609
Precautions for disconnecting and connecting air conditioner piping 1612
Handling of compressor oil 1614
Desiccant replacement 1616
90 Diagrams and drawings 1619
Table of contents 1620
Hydraulic circuit diagram 1621
Symbols in hydraulic circuit diagram 1621
Hydraulic circuit diagram 1625
Electric circuit diagram 1626
Symbols in electric circuit diagram 1626
Electric circuit diagram 1630
Electric circuit diagram for air conditioner unit 1636
INDEX1637

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24