Komatsu PC210i-10 PC210LCi-10 Hydraulic Excavator Shop Manual PDF

Description

Komatsu PC210i-10 PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC210i-10 PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-04 – PDF DOWNLOAD 

Language : English
Pages : 2444
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC210i-10 PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-04 – PDF DOWNLOAD 

SERIAL NUMBERS 451080 and up

How to read the shop manual
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
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
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu PC210i-10 PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-04 – PDF DOWNLOAD 

SERIAL NUMBERS 451080 and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 18
Important safety notice 18
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling equipment of fuel system devices 29
Handling of intake system parts 30
Handling of hydraulic equipment 31
Method of disconnecting and connecting of push-pull type coupler 33
Handling of electrical equipment 36
How to read electric wire code 44
Precautions when performing operation 47
Practical use of KOMTRAX 52
Standard tightening torque table 53
List of abbreviation 59
Conversion table 64
01 Specification 69
Table of contents 70
Specifications 71
Specification drawing 71
Working range drawings 73
Specifications 75
Weight table 81
Table of fuel, coolant, and lubricants 85
10 Structure and function 87
Table of contents 88
Engine and cooling system 89
Engine related parts 89
KVGT 91
EGR system piping drawing 98
EGR system circuit diagram 100
EGR valve 102
EGR cooler 104
KCCV layout drawing 106
KCCV ventilator 108
KDPF 110
Cooling system 114
Power train 116
Power train system 116
Swing circle 118
Swing machinery 119
Final drive 121
Undercarriage and frame 123
Track frame and idler cushion 123
Hydraulic system 125
Hydraulic component layout 125
Valve control 127
Hydraulic tank 129
CLSS 131
Main pump 136
Control valve 162
Swing motor 219
Travel motor 231
PPC valve 244
Solenoid valve 267
Attachment circuit selector valve (for high pressure circuit) 270
Attachment circuit selector valve (for low pressure circuit) 272
Center swivel joint 275
Accumulator 277
EPC valve for intelligent Machine Control 278
Work equipment 283
Work equipment 283
Work equipment shim 284
Bucket play adjustment shim 285
Cab and its attachments 286
Cab mount and cab tipping stopper 286
ROPS cab 287
Electrical system 288
Electrical control system 288
Machine monitor system 378
KOMTRAX system 401
Sensor 404
20 Standard value tables 443
Table of contents 444
Standard service value table 445
Standard value table for engine 445
Standard value table for machine 447
Standard value table for electrical system 465
30 Testing and adjusting 475
Table of contents 476
Related information on testing and adjusting 477
Tools for testing and adjusting 477
Sketch of tools for testing and adjusting 485
Engine and cooling system 486
Testing engine speed 486
Testing boost pressure 487
Testing exhaust gas color 489
Testing and adjusting valve clearance 491
Testing compression pressure 494
Testing blowby pressure 498
Testing engine oil pressure 499
Testing EGR valve and KVGT oil pressures 500
Measuring fuel pressure 501
Measuring fuel delivery, return and leakage 507
Bleeding air from fuel system 512
Testing fuel circuit for leakage 514
Handling cylinder cutout mode operation 515
Handling no-injection cranking operation 516
Testing and adjusting air conditioner compressor belt tension 517
Replacing fan belt 519
Power train 520
Testing swing circle bearing clearance 520
Undercarriage and frame 521
Testing and adjusting track tension 521
Hydraulic system 522
Releasing remaining pressure from hydraulic circuit 522
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 527
Testing oil pressure of control circuit 531
Testing and adjusting oil pressure in pump PC control circuit 534
Testing and adjusting oil pressure in pump LS control circuit 537
Testing output pressure of solenoid valve 542
Testing PPC valve output pressure 546
Adjusting play of work equipment and swing PPC valves 548
Testing pump swash plate sensor 549
Isolating the parts causing hydraulic drift in work equipment 550
Testing oil leakage 552
Bleeding air from hydraulic circuit 555
Cab and its attachments 557
Testing cab tipping stopper 557
Adjusting mirrors 558
Electrical system 560
Special functions of machine monitor 560
Special function of control box 847
KOMTRAX terminal start-up procedure 978
Adjusting rearview camera angle 981
Handling voltage circuit of engine controller 983
Handling battery disconnect switch 984
Testing diodes 985
Pm clinic 986
Pm Clinic service 986
40 Troubleshooting 997
Table of contents 998
Related information on troubleshooting 1007
Troubleshooting points 1007
Sequence of events in troubleshooting 1009
Testing before troubleshooting 1011
Inspection procedure before troubleshooting 1013
Preparation for troubleshooting of electrical system 1032
Classification and procedure for troubleshooting 1040
Symptom and troubleshooting numbers 1043
Information in troubleshooting table 1046
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 1048
Connector list and layout 1050
Connector contact identification 1063
T-branch box and T-branch adapter table 1102
Fuse location table 1107
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 1110
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 1113
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 1114
Failure codes table 1115
Troubleshooting by failure code (Display of code) 1127
Failure code [879AKA] A/C Inner Sensor Open Circuit 1127
Failure code [879AKB] A/C Inner Sensor Short Circuit 1128
Failure code [879BKA] A/C Outer Sensor Open Circuit 1129
Failure code [879BKB] A/C Outer Sensor Short Circuit 1130
Failure code [879CKA] Ventilating Sensor Open Circuit 1131
Failure code [879CKB] Ventilating Sensor Short Circuit 1132
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 1133
Failure code [879EMC] Ventilation Damper Abnormality 1134
Failure code [879FMC] Air Mix Damper Abnormality 1135
Failure code [879GKX] Refrigerant Abnormality 1136
Failure code [989L00] Engine Controller Lock Caution1 1137
Failure code [989M00] Engine Controller Lock Caution2 1138
Failure code [989N00] Engine Controller Lock Caution3 1139
Failure code [A1U0N3] HC Desorb Request 1 1140
Failure code [A1U0N4] HC Desorb Request 2 1142
Failure code [AA10NX] Air Cleaner Clogging 1144
Failure code [AB00KE] Charge Voltage Low 1146
Failure code [B@BAZG] Engine Oil Pressure Low 1148
Failure code [B@BAZK] Eng Oil Level Low 1149
Failure code [B@BCNS] Engine Coolant Overheat 1150
Failure code [B@BCZK] Radiator Coolant Level Low 1151
Failure code [B@HANS] Hyd Oil Overheat 1153
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1154
Failure code [CA122] Chg Air Press Sensor High Error 1155
Failure code [CA123] Chg Air Press Sensor Low Error 1157
Failure code [CA131] Throttle Sensor High Error 1159
Failure code [CA132] Throttle Sensor Low Error 1161
Failure code [CA144] Coolant Temp Sens High Error 1163
Failure code [CA145] Coolant Temp Sens Low Error 1165
Failure code [CA153] Chg Air Temp Sensor High Error 1167
Failure code [CA154] Chg Air Temp Sensor Low Error 1169
Failure code [CA187] Sensor 2 Supply Volt Low Error 1171
Failure code [CA221] Ambient Press Sensor High Error 1173
Failure code [CA222] Ambient Press Sensor Low Error 1175
Failure code [CA227] Sensor 2 Supply Volt High Error 1177
Failure code [CA234] Eng Overspeed 1178
Failure code [CA238] Ne Speed Sensor Supply Volt Error 1179
Failure code [CA239] Ne Speed Sens Supply Volt High Error 1180
Failure code [CA271] IMV/PCV1 Short Error 1181
Failure code [CA272] IMV/PCV1 Open Error 1183
Failure code [CA295] Ambient Press Sens In Range Error 1185
Failure code [CA322] Inj #1(L#1) Open/Short Error 1186
Failure code [CA323] Inj #5(L#5) Open/Short Error 1188
Failure code [CA324] Inj #3(L#3) Open/Short Error 1190
Failure code [CA325] Inj #6(L#6) Open/Short Error 1192
Failure code [CA331] Inj #2(L#2) Open/Short Error 1194
Failure code [CA332] Inj #4(L#4) Open/Short Error 1196
Failure code [CA343] ECM Critical Internal Failure 1198
Failure code [CA351] Injectors Drive Circuit Error 1199
Failure code [CA352] Sensor 1 Supply Volt Low Error 1200
Failure code [CA356] Mass Air Flow Sensor High Error 1202
Failure code [CA357] Mass Air Flow Sensor Low Error 1204
Failure code [CA386] Sensor 1 Supply Volt High Error 1206
Failure code [CA428] Water in Fuel Sensor High Error 1207
Failure code [CA429] Water in Fuel Sensor Low Error 1209
Failure code [CA435] Eng Oil Press Sw Error 1211
Failure code [CA441] Battery Voltage Low Error 1212
Failure code [CA442] Battery Voltage High Error 1214
Failure code [CA449] Rail Press Very High Error 1215
Failure code [CA451] Rail Press Sensor High Error 1216
Failure code [CA452] Rail Press Sensor Low Error 1218
Failure code [CA488] Chg Air Temp High Torque Derate 1220
Failure code [CA515] Rail Press Sens Sup Volt High Error 1221
Failure code [CA516] Rail Press Sens Sup Volt Low Error 1223
Failure code [CA553] Rail Press High Error 1225
Failure code [CA555] Crankcase Press High Error 1 1226
Failure code [CA556] Crankcase Press High Error 2 1227
Failure code [CA559] Rail Press Low Error 1228
Failure code [CA595] Turbo Speed High Error 2 1230
Failure code [CA687] Turbo Speed Low Error 1231
Failure code [CA689] Eng Ne Speed Sensor Error 1233
Failure code [CA691] Intake Air Temp Sens High Error 1235
Failure code [CA692] Intake Air Temp Sens Low Error 1237
Failure code [CA697] ECM Int Temp Sensor High Error 1239
Failure code [CA698] ECM Int Temp Sensor Low Error 1240
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1241
Failure code [CA778] Eng Bkup Speed Sensor Error 1243
Failure code [CA1117] Persistent Data Lost Error 1248
Failure code [CA1664] KDOC Malfunction 1249
Failure code [CA1691] Regeneration Ineffective 1251
Failure code [CA1695] Sensor 5 Supply Volt High Error 1254
Failure code [CA1696] Sensor 5 Supply Volt Low Error 1255
Failure code [CA1843] Crankcase Press Sens High Error 1256
Failure code [CA1844] Crankcase Press Sens Low Error 1258
Failure code [CA1879] KDPF Delta P Sensor High Error 1260
Failure code [CA1881] KDPF Delta P Sensor Low Error 1262
Failure code [CA1883] KDPF Delta P Sens In Range Error 1264
Failure code [CA1921] KDPF Soot Load High Error 1 1267
Failure code [CA1922] KDPF Soot Load High Error 2 1270
Failure code [CA1942] Crankcase Press Sens In Range Error 1275
Failure code [CA1993] KDPF Delta Pressure Low Error 1276
Failure code [CA2185] Throt Sensor Sup Volt High Error 1279
Failure code [CA2186] Throt Sensor Sup Volt Low Error 1281
Failure code [CA2249] Rail Press Very Low Error 1283
Failure code [CA2271] EGR Valve Pos Sens High Error 1284
Failure code [CA2272] EGR Valve Pos Sens Low Error 1286
Failure code [CA2288] Turbo Speed High Error 1 1289
Failure code [CA2311] IMV Solenoid Error 1290
Failure code [CA2349] EGR Valve Solenoid Open Error 1291
Failure code [CA2353] EGR Valve Solenoid Short Error 1293
Failure code [CA2357] EGR Valve Servo Error 1295
Failure code [CA2373] Exhaust Manifold Press Sens High error 1296
Failure code [CA2374] Exhaust Manifold Press Sens Low error 1298
Failure code [CA2375] EGR Orifice Temp Sens High Error 1300
Failure code [CA2376] EGR Orifice Temp Sens Low Error 1302
Failure code [CA2381] KVGT Pos Sens High Error 1304
Failure code [CA2382] KVGT Pos Sens Low Error 1306
Failure code [CA2383] KVGT Solenoid Open Error 1309
Failure code [CA2386] KVGT Solenoid Short Error 1311
Failure code [CA2387] KVGT Servo Error 1313
Failure code [CA2554] Exh Manifold Press Sens In Range Error 1314
Failure code [CA2555] Grid Htr Relay Volt Low Error 1315
Failure code [CA2556] Grid Htr Relay Volt High Error 1317
Failure code [CA2637] KDOC Face Plugging 1319
Failure code [CA2639] Manual Stationary Regeneration Request 1321
Failure code [CA2961] EGR Orifice Temp High Error 1 1324
Failure code [CA2973] Chg Air Press Sensor In Range Error 1325
Failure code [CA3133] KDPF Outlet Press Sens High Error 1326
Failure code [CA3134] KDPF Outlet Press Sens Low Error 1328
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 1330
Failure code [CA3251] KDOC Inlet Temp High Error 1334
Failure code [CA3253] KDOC Temp Error – Non Regeneration 1337
Failure code [CA3254] KDOC Outlet Temp High Error 1 1340
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1343
Failure code [CA3256] KDPF Outlet Temp High Error 1 1346
Failure code [CA3311] KDOC Outlet Temp High Error 2 1349
Failure code [CA3312] KDPF Outlet Temp High Error 2 1352
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1355
Failure code [CA3314] KDOC Inlet Temp Sens High Error 1358
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 1362
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 1366
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1369
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1373
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1377
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 1381
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1384
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1388
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 1390
Failure code [CA3741] Rail Press Valve Trip Error 1392
Failure code [D110KB] Battery Relay Output Voltage 1393
Failure code [D19JKZ] Personal Code Relay Abnormality 1395
Failure code [D811MC] KOMTRAX Error 1398
Failure code [D862KA] GPS Antenna Open Circuit 1399
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 1400
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1402
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1403
Failure code [DA20MC] Pump Controller 1404
Failure code [DA22KK] Pump Solenoid Power Low Error 1405
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 1407
Failure code [DA29KQ] Model Selection Abnormality 1409
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 1411
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 1413
Failure code [DA2QKR] CAN2 Discon (Pump Con) 1414
Failure code [DA2RKR] CAN1 Discon (Pump Con) 1416
Failure code [DAF0MB] Monitor ROM Abnormality 1417
Failure code [DAF0MC] Monitor Error 1418
Failure code [DAF8KB] Camera Power Supply Short Circuit 1419
Failure code [DAF9KQ] Model Selection Abnormality 1421
Failure code [DAFGMC] GPS Module Error 1422
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 1423
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 1425
Failure code [DAFQKR] CAN2 Discon (Monitor) 1426
Failure code [DAZ9KQ] A/C Model Selection Abnormality 1427
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1428
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1433
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1439
Failure code [DB90KT] W/E Controller Internal Failure 1446
Failure code [DB90MC] W/E Controller Reset 1447
Failure code [DB92KK] W/E CON Solenoid Power Voltage Low Error 1448
Failure code [DB95KP] W/E CON 5V Sensor 0 Power Volt Low Error 1450
Failure code [DB96KP] W/E CON 5V Sensor 1 Power Volt Low Error 1453
Failure code [DB99KQ] Model Selection Signal Mismatch (W/E Con) 1457
Failure code [DB9LKA] Operating Lamp Open Circuit (W/E CON) 1460
Failure code [DB9LKB] Operating Lamp Hot Short Circuit (W/E CON) 1462
Failure code [DB9QKR] CAN2 Defective Communication (W/E CON) 1464
Failure code [DB9RKR] CAN1 Defective Communication (W/E CON) 1466
Failure code [DBR0KT] ICT Sensor Controller Internal Failure 1468
Failure code [DBR0MC] ICT Sensor Controller Reset 1469
Failure code [DBR2KK] ICT/S CON Solenoid Power Low Error 1470
Failure code [DBR5KP] ICT/S CON 5V Sensor 0 Power Abnormality 1472
Failure code [DBR6KP] ICT/S CON 5V Sensor 1 Power Abnormality 1474
Failure code [DBR9KQ] Model Selection Signal Mismatch (ICT Sens) 1476
Failure code [DBRLKA] Operating Lamp Open Circuit (ICT/S CON) 1479
Failure code [DBRLKB] Operating Lamp Short Circuit (ICT/S CON) 1481
Failure code [DBRQKR] CAN2 Discon (ICT/S CON) 1483
Failure code [DBRRKR] CAN 1 Discon (ICT/S CON) 1486
Failure code [DBRSKB] ICT/S Con Battery Relay Drive Short Cir 1489
Failure code [DBRTKB] Control Box Activation Output Short Circuit (ICT Sensor Controller) 1491
Failure code [DBUSKR] Ethernet 0 Discon (GNSS Receiver) 1492
Failure code [DD20MA] Auto/Manual Selector Switch Error 1495
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 1497
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1499
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1500
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1503
Failure code [DHS3MA] Arm IN PPC Press Sens Defective Function 1506
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Def Function 1508
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function 1510
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function 1512
Failure code [DHSAMA] Swing RH PPC Press Sens Def Function 1514
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 1516
Failure code [DHSCMA] Arm Dump PPC Press Sens Def Function 1518
Failure code [DHSDMA] Bucket Dump PPC Press Sens Def Function 1520
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 1522
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 1525
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 1528
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 1531
Failure code [DK80KM] IMU Calibration Not Complete 1534
Failure code [DK80KR] IMU Defective Communication 1535
Failure code [DK80KT] IMU Error 1536
Failure code [DKG1KM] Bucket Cylinder Calibration Not Complete 1537
Failure code [DKG1L8] Bucket Cyl Stroke Sensor Inrange Error 1538
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality 1539
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality 1541
Failure code [DKT0KM] Boom Cylinder Calibration Not Complete 1543
Failure code [DKT0L8] Boom Cyl Stroke Sensor Inrange Error 1544
Failure code [DKT1KA] Boom Cyl Stroke Sensor A Open Circuit 1545
Failure code [DKT1KB] Boom Cyl Stroke Sensor A Short Circuit 1547
Failure code [DKT2KA] Boom Cyl Stroke Sensor B Open Circuit 1548
Failure code [DKT2KB] Boom Cyl Stroke Sensor B Short Circuit 1550
Failure code [DKT4KM] Arm Cylinder Calibration Not Complete 1551
Failure code [DKT4L8] Arm Cylinder Stroke Sensor Inrange Error 1552
Failure code [DKT5KA] Arm Cyl Stroke Sensor A Open Circuit 1553
Failure code [DKT5KB] Arm Cyl Stroke Sensor A Short Circuit 1555
Failure code [DKT6KA] Arm Cyl Stroke Sensor B Open Circuit 1557
Failure code [DKT6KB] Arm Cyl Stroke Sensor B Short Circuit 1559
Failure code [DKT8KA] Bucket Cyl Stroke Sensor A Open Circuit 1561
Failure code [DKT8KB] Bucket Cyl Stroke Sensor A Short Circuit 1563
Failure code [DKT9KA] Bucket Cyl Stroke Sensor B Open Circuit 1565
Failure code [DKT9KB] Bucket Cyl Stroke Sensor B Short Circuit 1567
Failure code [DKTAKA] Bucket Cyl Stroke Reset Sens Open Circuit 1569
Failure code [DKTAKB] Bucket Cyl Stroke Reset Sens Short Circuit 1571
Failure code [DKTAMB] Bucket Cyl Stroke Reset Sens Inrange Error 1573
Failure code [DKTBKX] Boom Cyl Stroke Reset Enc A,B Abnormality 1574
Failure code [DKTBMC] Boom Cylinder Stroke Reset Encoder Error 1576
Failure code [DKTEMB] Boom Cyl Stroke Reset Enc Z Abnormality 1577
Failure code [DKTFKX] Boom Cyl Stroke Reset Enc A,B Abnormality 1579
Failure code [DKTFMC] Arm Cyl Stroke Reset Enc Error 1581
Failure code [DKTJMB] Arm Cyl Stroke Reset Enc Z Abnormality 1582
Failure code [DKU1MA] Boom Spool Stroke Sensor In Range Error 1584
Failure code [DKU2MA] Arm Spool Storke Sensor In Range Error 1585
Failure code [DKUGKA] Arm IN PPC Reduce Press EPC Open Circuit 1586
Failure code [DKUGKB] Arm IN PPC Reduce Press EPC Ground Fault 1588
Failure code [DKUGKY] Arm IN PPC Reduce Pressure EPC Hot Short 1589
Failure code [DKUHKA] Arm OUT PPC Reduce Press EPC Open Circuit 1591
Failure code [DKUHKB] Arm OUT PPC Reduce Press EPC Ground Fault 1593
Failure code [DKUHKY] Arm OUT PPC Reduce Pressure EPC Hot Short 1594
Failure code [DKV0KA] Boom Spool Stroke Sensor 1 Open Circuit 1596
Failure code [DKV0KY] Boom Spool Stroke Sensor 1 Hot Short Cir 1598
Failure code [DKV1KA] Arm Spool Stroke Sensor 1 Open Circuit 1600
Failure code [DKV1KY] Arm Spool Stroke Sensor 1 Hot Short Cir 1602
Failure code [DKV2KA] Boom Spool Stroke Sensor 2 Open Circuit 1604
Failure code [DKV2KY] Boom Spool Stroke Sensor 2 Hot Short Cir 1606
Failure code [DKV3KA] Arm Spool Stroke Sensor 2 Open Circuit 1608
Failure code [DKV3KY] Arm Spool Stroke Sensor 2 Hot Short Cir 1610
Failure code [DKV4MA] Boom RAISE PPC Press Sensor 2 Def Function 1612
Failure code [DKV5MA] Boom LOWER PPC Press Sensor 2 Def Function 1614
Failure code [DKV6MA] Arm OUT PPC Press Sensor 2 Def Function 1617
Failure code [DKV7MA] Arm IN PPC Press Sens 2 Defective Function 1620
Failure code [DKV8MA] Bucket DUMP PPC Press Sens 2 Def Function 1623
Failure code [DKV9MA] Bucket CURL PPC Press Sens 2 Def Function 1625
Failure code [DKVAMA] PPC Source Press Sensor Error 1627
Failure code [DKVBKA] Bucket CURL PPC Reduce Press EPC Open Cir 1629
Failure code [DKVBKB] Bucket CURL PPC Reduce Press EPC Grd Fault 1631
Failure code [DKVBKY] Bucket CURL PPC Reduce Press EPC Hot Short 1632
Failure code [DKVCKA] Boom RAISE PPC Intervention EPC Open Cir 1634
Failure code [DKVCKB] Boom RAISE PPC Intervention EPC Grnd Fault 1636
Failure code [DKVCKY] Boom RAISE PPC Intervention EPC Hot Short 1638
Failure code [DKVDKA] Boom RAISE EPC Cut Relay Open Circuit 1641
Failure code [DKVDKB] Boom RAISE EPC Cut Relay Ground Fault 1642
Failure code [DKVDKY] Boom RAISE EPC Cut Relay Hot Short Circuit 1644
Failure code [DKVDMA] Boom RAISE EPC Cut Relay Error 1645
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 1646
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 1648
Failure code [DV20KB] Travel Alarm Short Circuit 1650
Failure code [DW43KA] Travel Speed Sol Open Circuit 1652
Failure code [DW43KB] Travel Speed Sol Short Circuit 1654
Failure code [DW45KA] Swing holding brake Sol Open Circuit 1656
Failure code [DW45KB] Swing holding brake Sol Short Circuit 1659
Failure code [DW4FKA] Boom LOWER PPC Reduce Press EPC Open Cir 1661
Failure code [DW4FKB] Boom LOWER PPC Reduce Press EPC Grnd Fault 1663
Failure code [DW4FKY] Boom LOWER PPC Reduce Press EPC Hot Short 1665
Failure code [DW4GKA] Boom RAISE PPC Reduce Press EPC Open Cir 1667
Failure code [DW4GKB] Boom RAISE PPC Reduce Press EPC Grnd Fault 1669
Failure code [DW4GKY] Boom RAISE PPC Reduce Press EPC Hot Short 1671
Failure code [DW4SKA] Bucket DUMP PPC Reduce Press EPC Open Cir 1673
Failure code [DW4SKB] Bucket DUMP PPC Reduce Press EPC Grd Fault 1675
Failure code [DW4SKY] Bucket DUMP PPC Reduce Press EPC Hot Short 1676
Failure code [DW91KA] Travel Junction Sol Open Circuit 1678
Failure code [DW91KB] Travel Junction Sol Short Circuit 1680
Failure code [DWA2KA] Attachment Sol Open Circuit 1682
Failure code [DWA2KB] Attachment Sol Short Circuit 1684
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit 1686
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 1688
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1690
Failure code [DWK2KB] Variable Back Press Sol Short Circuit 1692
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1694
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit 1696
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 1698
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1700
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 1702
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1704
Failure code [DXE0KA] LS-EPC Sol Open Circuit 1706
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1708
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1710
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 1712
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1714
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit 1716
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1718
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit 1720
Failure code [DY20KA] Wiper Working Abnormality 1722
Failure code [DY20MA] Wiper Parking Abnormality 1724
Failure code [DY2CKB] Washer Drive Short Circuit 1726
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 1728
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 1730
Failure code [H16SL8] Boom cylinder stroke sensor rotor stuck 1732
Failure code [H17SL8] Arm cylinder stroke sensor rotor stuck 1733
Troubleshooting of electrical system (E-mode) 1734
E-1 Engine does not start (Engine does not crank) 1734
E-2 Manual preheating system does not work 1740
E-3 Automatic preheating system does not work 1743
E-4 Preheating monitor does not light up when preheater is operated 1745
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1747
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow 1750
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow 1751
E-8 Coolant temperature monitor lights up in white while engine is running 1752
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1753
E-10 Charge level monitor lights up while engine is running 1754
E-11 Fuel level monitor lights up in red while engine is running 1755
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 1756
E-13 Water separator monitor lights up while engine is running 1757
E-14 Coolant temperature monitor lights up in red while engine is running 1758
E-15 Hydraulic oil temperature monitor lights up in red while engine is running 1759
E-16 Engine oil pressure monitor lights up in red while engine is running 1760
E-17 Fuel gauge indicates either full or empty and does not move 1761
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 1762
E-19 Coolant temperature gauge indicates either Min or Max and does not move 1763
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max ) 1764
E-21 Hydraulic oil temperature gauge indicates either Min or Max and does not move 1765
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max ) 1767
E-23 Content of display on machine monitor is different from that of actual machine 1768
E-24 Machine monitor does not display some items 1769
E-25 Function switch does not work 1770
E-26 Automatic preheating system does not work (In cold season) 1771
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated 1772
E-28 Auto-deceleration is not actuated or canceled when lever is operated 1773
E-29 Working mode selection screen is not diplayed when working mode switch is operated 1774
E-30 Engine or hydraulic pump setting does not change when working mode is changed 1775
E-31 Travel speed monitor does not change when travel speed switch is operated 1776
E-32 Travel speed does not change while travel speed selection is changed 1777
E-33 Alarm buzzer does not stop sounding 1778
E-34 When starting switch is turned to OFF position, service meter is not displayed 1779
E-35 Service mode cannot be selected 1780
E-36 Any of work equipment, swing and travel does not work 1781
E-37 Any of work equipment, swing and travel cannot be locked 1783
E-38 Machine cannot swing while swing brake cancel switch is canceled 1784
E-39 Swing brake does not operate while swing brake cancel switch is locked 1786
E-40 One-touch power maximizing function does not work or monitor is not displayed 1788
E-41 One-touch power maximizing function cannot be canceled 1790
E-42 Travel alarm does not sound when machine travels 1791
E-43 Alarm does not stop sounding while machine is stopped 1792
E-44 Horn does not sound 1793
E-45 Horn does not stop sounding 1795
E-46 Wiper monitor does not light up or go out when wiper switch is operated 1796
E-47 Wiper does not operate when wiper switch is operated 1797
E-48 Window washer does not operate when window washer switch is operated 1799
E-49 BOOM LOWER indication is not displayed properly with monitoring function 1800
E-50 ARM DUMP indication is not displayed properly with monitoring function 1801
E-51 ARM IN indication is not displayed properly with monitoring function 1802
E-52 BOOM RAISE indication is not displayed properly with monitoring function 1803
E-53 BUCKET CURL indication is not displayed properly with monitoring function 1804
E-54 BUCKET DUMP indication is not displayed properly with monitoring function 1805
E-55 SWING indication is not displayed properly with monitoring function 1806
E-56 TRAVEL indication is not displayed properly with monitoring function 1807
E-57 Service is not displayed properly with monitoring function 1808
E-58 Attachment hydraulic circuit cannot be changed 1811
E-59 KOMTRAX system does not operate normally 1812
E-60 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1814
E-61 Control box displays the message [GPS receiver not connected!] 1819
E-62 Control box displays the message [Waiting for radio link ] 1822
E-63 Control box displays the message [Tilt Bucket Sensor Offline!] 1823
E-64 Control box displays the message [Waiting for satellites ] 1824
E-65 Control box displays the message [Komatsu controller not connected!] 1825
E-66 Control box displays the message [Sensors are invalid] 1828
E-67 Control box displays the message [Waiting to initialize ] 1830
E-68 Control box displays the message [Initializing ] 1831
E-69 Control box displays the message [No GPS Localization ] 1832
E-70 Control box displays the message [Low precisions ] 1833
E-71 Control box displays [Out of design area ] 1834
E-72 Control box displays [Avoidance Area Breach] 1835
E-73 Control box can not be turned on 1836
E-74 Control box does not display intelligent Machine Control screen 1837
E-75 Control box does not display hydraulic excavator image 1838
E-76 Control box does not display design surface 1839
E-77 Control box touch panel does not respond 1840
E-78 Control box touch panel is inaccurate 1841
E-79 When checking and adjusting the bucket edge position, the value is different from actual machine 1842
E-80 When pressing auto/manual switch, Semi-auto limited digging mode is not displayed 1844
E-81 Automatic leveling assist function does not work while Semi-auto limited digging mode is displayed 1845
E-82 Automatic stop control function does not work while Semi-auto limited digging mode is displayed 1846
E-83 Blade edge position on design surface is not accurate when automatic leveling assist function is on 1847
E-84 Blade edge stop position is not accurate for design surface when automatic stop control function is on 1849
E-85 Opposite direction compass does not show the opposite direction 1851
E-86 NG occurs very often in IMU calibration diagnosis 1852
E- 87 Boom RAISE end cushion does not work at all or worksinsufficiently 1853
E-88 Arm IN end cushion does not work at all or works insufficiently 1854
Troubleshooting of hydraulic and mechanical system (H-mode) 1857
Information described in troubleshooting table (H-mode) 1857
System chart for hydraulic system 1858
Failure mode and cause table 1860
H-1 All of work equipment, swing and travel operation lacks speed or power 1868
H-2 Engine speed drops significantly or engine stalls 1871
H-3 All work equipment, swing and travel does not work 1874
H-4 Unusual sound is heard from around hydraulic pump 1875
H-5 Fine control performance or response is poor 1876
H-6 Boom speed or power is low 1878
H-7 Arm speed or power is low 1882
H-8 Bucket speed or power is low 1887
H-9 Work equipment does not move in single operation 1890
H-10 Hydraulic drift of boom is large 1891
H-11 Hydraulic drift of arm is large 1892
H-12 Hydraulic drift of bucket is large 1893
H-13 Time lag of work equipment is large 1894
H-14 When part of work equipment is relieved singly, other parts of work equipment move 1896
H-15 One-touch power maximizing function does not operate 1897
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1898
H-17 In combined operations of swing and boom RAISE, boom rising speed is low 1899
H-18 In combined operations of swing and travel, travel speed drops largely 1900
H-19 Machine does not travel straight 1901
H-20 Travel speed is slow 1904
H-21 Machine is hard to steer or travel power is low 1906
H-22 Travel speed does not change, or travel speed is too slow or fast 1909
H-23 One of tracks does not run 1910
H-24 Upper structure does not swing to the right or left 1912
H-25 Upper structure swing only to the right or left 1913
H-26 Swing acceleration or swing speed is low in both directions (right and left) 1914
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction 1915
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1916
H-29 Upper structure overruns excessively when it stops swinging (either right or left) 1917
H-30 Shock is large when upper structure stops swinging 1918
H-31 Large unusual noise is heard when upper structure stops swinging 1919
H-32 Swing drift on a slope is large while swing holding brake is applied 1920
H-33 Swing drift on a slope is large while swing holding brake is released 1921
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed 1922
H-35 Oil flow in attachment circuit cannot be controlled 1923
H-36 All work equipment do not operate 1924
Troubleshooting of engine (S-mode) 1925
Information mentioned in troubleshooting table (S mode) 1925
S-1 When starting switch is turned to START position, engine does not crank 1926
S-2 Engine cranks but no exhaust smoke comes out 1927
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1928
S-4 Engine startability is poor 1929
S-5 Engine does not pick up smoothly 1931
S-6 Engine stops during operation 1933
S-7 Engine runs rough or is unstable 1935
S-8 Engine lacks power 1936
S-9 Exhaust smoke is black (KDPF clogs up early) 1938
S-10 Engine oil consumption is excessive 1940
S-11 Engine oil becomes contaminated early 1941
S-12 Fuel consumption is excessive 1942
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1943
S-14 Engine oil pressure drops 1944
S-15 Fuel is contaminated in engine oil 1945
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) 1946
S-17 Coolant temperature rises too high (overheating) 1947
S-18 Unusual noise is heard 1948
S-19 Vibration is excessive 1949
S-20 Air cannot be bled from fuel circuit 1950
S-21 Active regeneration is executed frequently 1951
S-22 Active regeneration takes time 1952
S-23 White smoke is exhausted during active regeneration 1953
50 Disassembly and assembly 1955
Table of contents 1956
Related information on disassembly and assembly 1958
How to read this manual 1958
Coating materials list 1960
Special tools list 1964
Sketches of special tools 1969
Engine and cooling system 1973
Removal and installation of supply pump assembly 1973
Removal and installation of injector assembly 1978
Removal and installation of cylinder head assembly 1987
Removal and installation of radiator assembly 2007
Removal and installation of hydraulic oil cooler assembly 2009
Removal and installation of aftercooler assembly 2012
Removal and installation of engine and main pump assembly 2014
Removal and installation of engine front oil seal 2026
Removal and installation of engine rear oil seal 2030
Removal and installation of fuel cooler assembly 2033
Removal and installation of fuel tank assembly 2034
Removal and installation of engine hood assembly 2037
Removal and installation of KDPF assembly 2040
Disassembly and assembly of KDPF assembly 2048
Removal and installation of KCCV assembly 2056
Removal and installation of air cleaner assembly 2060
Power train 2063
Removal and installation of travel motor and final drive assembly 2063
Disassembly and assembly of final drive 2064
Removal and installation of swing motor and swing machinery assembly 2072
Disassembly and assembly of swing machinery 2075
Removal and installation of swing circle assembly 2082
Undercarriage and frame 2083
Separation and connection of track shoe assembly 2083
Removal and installation of sprocket 2086
Removal and installation of idler and idler cushion assembly 2087
Disassembly and assembly of idler assembly 2088
Disassembly and assembly of idler cushion 2091
Disassembly and assembly of track roller assembly 2093
Disassembly and assembly of carrier roller 2095
Removal and installation of revolving frame assembly 2098
Removal and installation of counterweight assembly 2100
Hydraulic system 2103
Removal and installation of center swivel joint assembly 2103
Disassembly and assembly of center swivel joint 2106
Removal and installation of hydraulic tank assembly 2107
Removal and installation of main pump assembly 2111
Removal and installation of control valve assembly 2115
Disassembly and assembly of control valve 2122
Removal and installation of junction block assembly for Intelligent Machine Control 2127
Removal and installation of pressure sensor for Intelligent Machine Control 2130
Removal and installation of boom spool stroke sensor 2132
Removal and installation of arm spool stroke sensor 2133
Disassembly and assembly of work equipment PPC valve 2134
Disassembly and assembly of travel PPC valve 2136
Work equipment 2139
Removal and installation of work equipment assembly 2139
Disassembly and assembly of work equipment cylinder assembly 2143
Cab and its attachments 2159
Removal and installation of operator’s cab assembly 2159
Removal and installation of operator cab glass (adhered glass) 2165
Removal and installation of front window assembly 2175
Removal and installation of floor frame assembly 2181
Removal and installation of air conditioner unit assembly 2187
Removal and installation of operator’s seat 2193
Removal and installation of seat belt 2196
Removal and installation of front wiper assembly 2198
Electrical system 2205
Removal and installation of air conditioner compressor assembly 2205
Removal and installation of air conditioner condenser assembly 2208
Removal and installation of engine controller assembly 2210
Removal and installation of pump controller assembly 2212
Removal and installation of machine monitor assembly 2216
Removal and installation of pump swash plate sensor 2219
Removal and installation of mass air flow and temperature sensor 2220
Removal and installation of KOMTRAX terminal assembly 2221
Removal and installation of ICT sensor controller assembly 2223
Removal and installation of junction harness of control box 2225
Removal and installation of control box harness 2227
Removal and installation of work equipment controller assembly 2228
Removal and installation of GNSS receiver 2230
Removal and installation of radio device and site link 2232
Removal and installation of GNSS antenna 2234
Removal and installation of IMU sensor 2236
60 Maintenance standard 2237
Table of contents 2238
Engine and cooling system 2239
Engine mount 2239
Cooling system 2240
Power train 2241
Swing circle 2241
Swing machinery 2242
Final drive 2244
Sprocket 2246
Undercarriage and frame 2248
Track frame and idler cushion 2248
Idler 2250
Track roller 2252
Carrier roller 2253
Track shoe 2254
Hydraulic system 2260
Hydraulic tank 2260
Main pump 2261
Control valve 2262
Swing motor 2272
Travel motor 2274
Work equipment and swing PPC valve 2277
Travel PPC valve 2280
1st-line attachment PPC valve (with EPC valve) 2282
2nd-line attachment PPC valve 2285
Solenoid valve 2287
Attachment circuit selector valve (for high-pressure circuit) 2288
Attachment circuit selector valve (for low-pressure circuit) 2289
Center swivel joint 2290
Work equipment 2291
Work equipment 2291
Boom cylinder 2300
Stroke sensing boom cylinder 2301
Stroke sensing arm cylinder 2302
Stroke sensing bucket cylinder 2303
80 Appendix 2307
Table of contents 2308
Air conditioner components 2309
Precautions for refrigerant 2309
Air conditioner component 2310
Configuration and function of refrigeration cycle 2313
Outline of refrigeration cycle 2314
Air conditioner unit 2316
Dual pressure switch 2323
Air conditioner controller 2324
Compressor 2325
Air conditioner condenser 2326
Sunlight sensor 2328
Outer temperature sensor (outside air temperature sensor) 2329
Procedure for testing and troubleshooting 2330
Circuit diagram and arrangement of connector pins 2332
System diagram 2334
Input and output signals of the air conditioner controller 2335
Parts and connectors layout 2337
Testing air leakage (duct) 2341
Testing with self-diagnosis function 2345
Testing vent (mode) changeover 2348
Testing FRESH/RECIRC air changeover 2351
Testing sunlight sensor 2352
Testing (dual) pressure switch for refrigerant 2353
Testing relays 2354
Troubleshooting chart 1 2355
Troubleshooting chart 2 2356
Information in troubleshooting table 2359
Failure code list related to air conditioner 2360
Failure code [879AKA] A/C Inner Sensor Open Circuit 2361
Failure code [879AKB] A/C Inner Sensor Short Circuit 2362
Failure code [879BKA] A/C Outer sensor Open Circuit 2363
Failure code [879BKB] A/C Outer sensor Short Circuit 2365
Failure code [879CKA] Ventilating Sensor Open Circuit 2367
Failure code [879CKB] Ventilating Sensor Short Circuit 2368
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 2369
Failure code [879EMC] Ventilation Damper Abnormality 2371
Failure code [879FMC] Air Mix Damper Abnormality 2372
Failure code [879GKX] Refrigerant Abnormality 2373
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 2374
A-2 Troubleshooting of compressor system (Air is not cooled) 2376
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2379
A-4 Troubleshooting for FRESH/RECIRC air changeover 2381
Troubleshooting with gauge pressure 2383
Connection of service tool 2386
Precautions for disconnecting and connecting air conditioner piping 2388
Handling of compressor oil 2390
Desiccant replacement 2392
90 Diagrams and drawings 2395
Table of contents 2396
Hydraulic circuit diagram 2397
Symbols in hydraulic circuit diagram 2397
Electric circuit diagram 2405
Symbols in electric circuit diagram 2405
INDEX 2433

IMAGES PREVIEW OF THE MANUAL:

S.V  17/12/24